Intelligent hydraulic creeping formwork construction process for main tower of cable-stayed bridge

Abstract

The invention discloses a cable-stayed bridge main tower intelligent hydraulic creeping formwork construction technology which comprises the steps that firstly, after an embedded part system is embedded, concrete is poured, and foundation construction is completed; step 2, assembling a creeping formwork, pre-assembling a frame body, hoisting and installing a formwork unit, connecting a hydraulic oil pipe and a centralized pump station, arranging an intelligent control system and an intelligent maintenance system on the formwork, and debugging parameters of each system; thirdly, first climbing is conducted, construction parameters are detected through an intelligent control system, a centralized pump station is started, an upper reversing box, a lower reversing box and a hydraulic oil pipe act cooperatively, the guide rail and the frame body are jacked alternately, the guide rail is locked after climbing in place, a formwork is fixed, and a multiple anchoring structure of a climbing cone, a stress bolt and a high-strength screw is adopted for an embedded part system; the stress bolt penetrates through the frame body connecting plate and then is fastened, the frame body can be stably anchored to the bridge tower, and the frame body is prevented from deviating or losing stability. The invention belongs to the field of hydraulic creeping formwork construction processes, and particularly relates to an intelligent hydraulic creeping formwork construction process for a cable-stayed bridge main tower.

Description

Technical Field

[0001] This invention belongs to the technical field of hydraulic climbing formwork construction technology, specifically referring to a smart hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge. Background Technology

[0002] In the construction of the main tower of a cable-stayed bridge, the main tower, as the core load-bearing structure of the bridge, is characterized by its "high height, variable cross-section, and long construction period," which places stringent requirements on the "climbing stability, construction accuracy, and level of intelligence" of the formwork system. Traditional hydraulic climbing formwork construction technology has technical limitations when adapting to the complex construction scenario of cable-stayed bridge main towers, such as low automation, high safety risks, and poor maintenance effects, making it difficult to meet the development needs of modern bridge construction for "efficiency, precision, and intelligence."

[0003] Traditional hydraulic climbing formwork construction relies on manual operation of hydraulic hoses. During the climbing process, manual monitoring of parameters such as scaffold displacement and load is required, which is not only inefficient but also prone to tilting due to human error, potentially leading to slippage accidents. The embedded component system often uses single bolt anchoring, which is susceptible to loosening under the constantly changing vertical and horizontal wind loads during main tower construction, posing a risk of scaffold instability. Furthermore, traditional methods lack intelligent curing methods—manual watering is required after the main tower concrete is poured, making it difficult to accurately control humidity and temperature. Especially in high-altitude, windy conditions, the concrete is prone to cracking due to rapid water loss, affecting structural strength. Moreover, data from each construction stage (such as formwork installation, hydraulic commissioning, and curing monitoring) is isolated, making full-process visual management impossible and hindering construction quality traceability and risk warning. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention provides a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge.

[0005] The technical solution adopted by the present invention is as follows: The present invention proposes a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge, including: Step 1: After pouring concrete into the pre-embedded component system, the foundation construction is completed;

[0006] Step 2: Climbing formwork assembly, pre-assemble the frame, hoist and install the formwork units, connect the hydraulic oil pipes to the centralized pump station, set up the intelligent control system and intelligent maintenance system, and debug the parameters of each system;

[0007] Step 3: Initial Climbing. The construction parameters are detected by the intelligent control system, the centralized pump station is started, and the upper and lower reversing boxes and hydraulic oil pipes work together to achieve the alternating lifting of the guide rail and the frame. After climbing to the position, the guide rail is locked and the template is fixed.

[0008] Step 4: Cyclic construction: After tying the reinforcing bars and installing the embedded parts system, the formwork is closed and concrete is poured. Then the formwork is removed and the climbing continues. The operation is repeated until the bridge tower construction is completed.

[0009] Step 5: Climbing formwork dismantling. In the reverse order of installation, dismantle the intelligent maintenance system, external equipment of the intelligent control system, hydraulic oil pipes, formwork, frame and embedded parts system in sequence.

[0010] Furthermore, the embedded part system includes:

[0011] Embedded plates, embedded brackets, climbing cones, load-bearing bolts, and high-strength threaded rods;

[0012] The embedded plate is made of steel plate, and a high-strength screw is fixedly arranged on one side of the embedded plate, and a climbing cone is threaded on the high-strength screw;

[0013] The end of the climbing cone away from the high-strength screw is threadedly connected to a load-bearing bolt.

[0014] One end of the load-bearing bolt is connected to the internal thread of the climbing cone, and the other end passes through the frame connecting plate and is tightened with a nut to achieve the anchoring of the frame and the bridge tower.

[0015] The embedded part bracket is L-shaped, and the horizontal section is fixed to the top surface of the embedded part plate by a high-strength screw.

[0016] Furthermore, the template includes:

[0017] Plywood panels, I-beams, channel steel back ribs, end timber, and beam hooks;

[0018] One side of the plywood panel is fixed by a self-tapping bolt wooden I-beam, and the wooden I-beam is arranged longitudinally along the outer side of the plywood panel.

[0019] The side of the wooden I-beam away from the plywood panel is fixed with a channel steel back rib by welding.

[0020] The template is fixedly arranged with end timbers on top, and the end timbers are bolted to the channel steel back ribs and the wooden I-beams for template hoisting.

[0021] Furthermore, the hydraulic hose includes:

[0022] Hydraulic oil pipes, centralized pump station, guide rails, upper reversing box and lower reversing box;

[0023] The guide rail is fixedly arranged on the frame;

[0024] The hydraulic oil pipe adopts a double-acting piston cylinder, and the cylinder diameter is determined according to the load calculation of the frame. The piston rod end is equipped with a connecting lug plate.

[0025] Furthermore, the hydraulic oil pipe is connected to a centralized pump station, and the centralized pump station has a built-in high-pressure gear pump.

[0026] Furthermore, an upper reversing box and a lower reversing box are arranged on the guide rail, and the upper and lower reversing boxes have built-in pawl mechanisms that are respectively connected to the hydraulic oil pipe piston rod. The pawls inside the upper and lower reversing boxes are adapted to the guide rail slots for alternating locking and lifting of the guide rail and the frame.

[0027] Furthermore, an intelligent control system is arranged in the middle layer of the frame, and a PLC main controller is arranged inside the intelligent control system to receive sensor data and output control commands.

[0028] Furthermore, the template is equipped with an intelligent maintenance system, and the intelligent maintenance system contains a fogging machine and a spraying system to increase the humidity of the maintenance environment.

[0029] Furthermore, the glued panel is made of waterproof plywood with a thickness of ≥18mm;

[0030] The back rib of the channel steel is made of Q235 channel steel;

[0031] The I-beam is a solid wood square with a cross-section of 100mm × 100mm.

[0032] The beneficial effects achieved by the present invention using the above structure are as follows:

[0033] 1. The intelligent control system monitors construction parameters in real time and can automatically coordinate the actions of hydraulic oil pipes, including the upper and lower reversing boxes, hydraulic oil pipes and centralized pump station, to achieve automated control of the alternating lifting of the guide rail and frame. This eliminates the need for extensive manual intervention and adjustment, significantly reducing human error and time consumption.

[0034] 2. The embedded part system adopts a multi-anchoring structure of climbing cones, load-bearing bolts, and high-strength screws. The load-bearing bolts are tightened after passing through the frame connecting plate, which can stably anchor the frame to the bridge tower and avoid frame displacement or instability. The double-acting piston cylinder in the hydraulic oil pipe cooperates with the reversing box with the built-in pawl mechanism to realize the alternating locking of the guide rail and the frame, preventing the risk of slippage during the climbing process. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the adhesive panel used in the intelligent hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge proposed in this invention.

[0036] Figure 2 This is a schematic diagram of the channel steel back rib of the intelligent hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge proposed in this invention;

[0037] Figure 3 This is a schematic diagram of a wooden I-beam for a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge proposed in this invention;

[0038] Figure 4 This is a schematic diagram of the climbing cone of a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge proposed in this invention;

[0039] Figure 5 This is a schematic diagram of the embedded part bracket for a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge proposed in this invention;

[0040] Figure 6 This is a schematic diagram of the guide rail for a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge proposed in this invention;

[0041] Figure 7 This invention provides a flowchart of the climbing formwork process for a smart hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge.

[0042] Figure 8 This is a flowchart illustrating the dismantling process of a smart hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge, as proposed in this invention.

[0043] The components include: 1. Frame; 2. Formwork; 3. Channel steel back bracing; 4. Timber beam hooks; 5. End timber; 6. Timber I-beams; 7. Plywood panels; 8. Hydraulic oil pipes; 9. Embedded parts system; 10. Load-bearing bolts; 11. Climbing cones; 12. High-strength bolts; 13. Embedded parts plates; 14. Embedded parts brackets; 15. Guide rails; 16. Upper reversing box; 17. Lower reversing box; 18. Hydraulic oil pipes; 19. Centralized pump station;

[0044] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. Detailed Implementation

[0045] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0046] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0047] like Figures 1-7As shown, this invention proposes a smart hydraulic climbing formwork construction process for the main tower of a cable-stayed bridge, including: Step 1: After the pre-embedded part system 9 is installed, concrete is poured to complete the foundation construction;

[0048] Step 2: Climbing formwork assembly, pre-assemble frame 1, hoist and install template unit 2, connect hydraulic oil pipe 8 to centralized pump station 19, set up intelligent control system and intelligent maintenance system, and debug the parameters of each system;

[0049] Step 3: Initial climbing. The construction parameters are detected by the intelligent control system, and the centralized pump station 19 is started. The upper reversing box 16, the lower reversing box 17 and the hydraulic oil pipe 18 work together to realize the alternating lifting of the guide rail 15 and the frame 1. After climbing to the position, the guide rail 15 is locked and the template 2 is fixed.

[0050] Step 4: Cyclic construction. After tying the reinforcing bars, install the embedded part system 9, close the formwork, and pour concrete. Then, after removing the formwork, continue climbing and repeat the operation until the bridge tower construction is completed.

[0051] Step 5: Climbing formwork dismantling. In the reverse order of installation, dismantle the intelligent maintenance system, intelligent control system external equipment, hydraulic oil pipe 8, formwork 2, frame 1 and embedded parts system 9 in sequence.

[0052] The embedded part system 9 includes: an embedded part plate 13, an embedded part bracket 14, a climbing cone 11, a load-bearing bolt 10, and a high-strength screw 12; the embedded part plate 13 is made of steel plate, and a high-strength screw 3 is fixedly arranged on one side of the embedded part plate 13, and a climbing cone 11 is threadedly connected to the high-strength screw 3; the end of the climbing cone 11 away from the high-strength screw 12 is threadedly connected to the load-bearing bolt 10; one end of the load-bearing bolt 10 is threadedly connected to the climbing cone 11, and the other end passes through the connecting plate of the frame 1 and is tightened with a nut to realize the anchoring of the frame 1 and the bridge tower; the embedded part bracket 14 is L-shaped, and the horizontal section is fixed to the top surface of the embedded part plate 13 by the high-strength screw 12.

[0053] In practical use, in the embedded part system 9, the embedded part plate 13 is connected to the climbing cone 11 through the high-strength screw 12, one end of the force-bearing bolt 10 is threaded to the climbing cone 11, and the other end passes through the connecting plate of the frame 1 and is fastened with a nut; the "L"-shaped embedded part bracket 14 is fixed to the top surface of the embedded part plate 13 through the high-strength screw 12, further strengthening the connection between the embedded part system and the bridge tower, constructing a stable anchoring structure, ensuring a reliable connection between the frame 1 and the bridge tower, and avoiding displacement or instability of the frame during climbing formwork construction.

[0054] The template 2 includes: plywood panel 7, I-beams 6, channel steel back ribs 3, end timber 5, and timber beam hooks 4; one side of the plywood panel 7 is fixed to the I-beams 6 by self-tapping bolts, and the I-beams 6 are arranged longitudinally along the outer side of the plywood panel 7; the side of the I-beams 6 away from the plywood panel 7 is fixed to the channel steel back ribs 3 by welding; end timber 5 is fixedly arranged on the top of the template 2, and the end timber 5 is connected to the channel steel back ribs 3 and the I-beams 6 by bolts for hoisting the template 2.

[0055] In practical use, the plywood panel 7 of template 2 is fixed to the wooden I-beam 6 with self-tapping bolts, and the channel steel back rib 3 is welded to the outside of the wooden I-beam 6; the end timber 5 is bolted to the channel steel back rib 3 and the wooden I-beam 6, which facilitates the hoisting of template 2, ensures the structural stability and flatness of template 2, reduces the leakage and deformation problems during concrete pouring, and facilitates the hoisting and installation of template, improving the efficiency of climbing formwork assembly.

[0056] The hydraulic oil pipe 8 includes: hydraulic oil pipe 18, centralized pump station 19, guide rail 15, upper reversing box 16 and lower reversing box 17; the guide rail 15 is fixedly arranged on the frame 1, the hydraulic oil pipe 18 adopts a double-acting piston cylinder, the cylinder diameter is determined according to the load calculation of the frame 1, and the piston rod end is provided with a connecting ear plate.

[0057] In practical use, the guide rail 15 of the hydraulic oil pipe 8 is fixed on the frame 1, using I-shaped steel and having 50mm interval slots on the side; the hydraulic oil pipe 18 is a double-acting piston cylinder, the cylinder diameter is determined according to the load of the frame 1, providing a stable guide rail structure and suitable power output for the alternating lifting of the climbing formwork, avoiding guide rail deformation or insufficient cylinder power during the climbing process, and ensuring the smoothness of the first climbing and the cyclic climbing.

[0058] The end timber 5 is an I-shaped steel section with a length of ≥6m and grooves spaced 50mm apart on its side along the height direction.

[0059] The hydraulic oil pipe 18 is connected to a centralized pump station 19, and the centralized pump station 19 has a built-in high-pressure gear pump.

[0060] In practical use, the hydraulic oil pipe 18 is connected to the centralized pump station 19. The centralized pump station 19 has a built-in high-pressure gear pump to provide stable and sufficient power to the hydraulic oil pipe 8, ensuring that the upper reversing box 16, the lower reversing box 17 and the hydraulic oil pipe 18 work together to achieve precise alternating lifting of the guide rail 15 and the frame 1.

[0061] The guide rail 15 is provided with an upper reversing box 16 and a lower reversing box 17. The upper reversing box 16 and the lower reversing box 17 have built-in pawl mechanisms that are respectively connected to the piston rod of the hydraulic oil pipe 18. The pawls inside the upper reversing box 16 and the lower reversing box 17 are adapted to the slots of the guide rail 15 for alternating locking and lifting of the guide rail 15 and the frame 1.

[0062] In practical use, the upper reversing box 16 and the lower reversing box 17 on the guide rail 15 have built-in pawl mechanisms, which are respectively connected to the piston rod of the hydraulic oil pipe 18. The pawl and the guide rail 15 are matched with the slot. During the climbing process, the guide rail 15 and the frame 1 are alternately fixed by locking and unlocking the pawl and the slot. The alternating lifting sequence of the guide rail 15 and the frame 1 is precisely controlled to avoid relative sliding between the guide rail and the frame during the climbing process, and to ensure that the guide rail and the frame can be reliably locked after climbing to the position.

[0063] The middle layer of frame 1 is equipped with an intelligent control system, which contains a PLC main controller to receive sensor data and output control commands.

[0064] In practical use, the intelligent control system located in the middle layer of frame 1 has a built-in PLC main controller, which receives sensor data and outputs control commands to realize intelligent monitoring and control of climbing formwork construction, timely detect abnormal parameters during the climbing process, avoid safety accidents, and improve construction accuracy and safety.

[0065] The template 2 is equipped with an intelligent maintenance system, which includes a fogging machine and a spraying system to increase the humidity of the maintenance environment.

[0066] In practical use, the intelligent curing system arranged on template 2 has a built-in fogging machine and spraying system. After the concrete is poured, the system increases the humidity of the curing environment by fogging or spraying, which corresponds to the requirement in the literature to "ensure proper curing after concrete pouring".

[0067] Effects: Provides a suitable curing environment for the poured bridge tower concrete, prevents cracks due to excessive water loss, ensures the concrete strength meets design requirements, and aligns with the foundation construction requirements of "ensuring the strength and stability of bridge tower concrete" outlined in the literature.

[0068] Among them, the plywood panel 7 is made of waterproof plywood with a thickness of ≥18mm; the channel steel back rib 3 is made of Q235 channel steel; and the wooden I-beam 6 is a solid wood square with a cross section of 100mm×100mm.

[0069] In practical use, the plywood panel 7 is made of waterproof plywood with a thickness of ≥18mm to prevent water seepage during concrete pouring, the channel steel back rib 3 is made of Q235 channel steel, and the wooden I-beam 6 is made of 100mm×100mm solid wood square to ensure that the formwork 2 has sufficient rigidity, waterproofness and support, reduce the problems of grout leakage and formwork deformation during concrete pouring, and ensure the appearance quality and structural strength of the bridge tower concrete.

[0070] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0071] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

[0072] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A smart hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge, characterized in that: include: Step 1: After the embedded parts system (9) is installed, concrete is poured to complete the foundation construction; Step 2: Climbing formwork assembly, pre-assemble the frame (1), hoist and install the template (2) unit, connect the hydraulic oil pipe (8) and the centralized pump station (19), arrange the intelligent control system and intelligent maintenance system on the template (2), and debug the parameters of each system; Step 3: First climb. The construction parameters are detected by the intelligent control system and the centralized pump station (19) is started. The upper reversing box (16), the lower reversing box (17) and the hydraulic oil pipe (18) work together to realize the alternating lifting of the guide rail (15) and the frame (1). After climbing to the position, the guide rail (15) is locked and the template (2) is fixed. Step 4: Cyclic construction, after binding the reinforcing bars, install the embedded parts system (9), then close the formwork and pour concrete, then remove the formwork and continue climbing, repeating the operation until the bridge tower construction is completed; Step 5: Climbing formwork removal. In the reverse order of installation, remove the intelligent maintenance system, intelligent control system external equipment, hydraulic oil pipe (8), formwork (2), frame (1) and embedded parts system (9) in sequence.

2. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 1, characterized in that: The embedded part system (9) includes: Embedded plate (13), embedded bracket (14), climbing cone (11), load-bearing bolt (10) and high-strength screw (12); The embedded plate (13) is made of steel plate, and a high-strength screw (3) is fixedly arranged on one side of the embedded plate (13), and a climbing cone (11) is threaded on the high-strength screw (3). The end of the climbing cone (11) away from the high-strength screw (12) is threaded with a load-bearing bolt (10); One end of the load-bearing bolt (10) is connected to the internal thread of the climbing cone (11), and the other end passes through the connecting plate of the frame (1) and is tightened with a nut to achieve the anchoring of the frame (1) and the bridge tower; The embedded part bracket (14) is L-shaped, and the horizontal section is fixed to the top surface of the embedded part plate (13) by a high-strength screw (12).

3. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 2, characterized in that: The template (2) includes: Plywood panel (7), I-beam (6), channel steel back rib (3), end timber (5) and timber beam hook (4); One side of the plywood panel (7) is fixed by a self-tapping bolt wooden beam (6), and the wooden beam (6) is arranged longitudinally along the outer side of the plywood panel (7); The side of the wooden I-beam (6) away from the plywood panel (7) is fixed by welding the channel steel back rib (3). The template (2) is fixedly arranged with end timber (5) above it, and the end timber (5) is connected to the channel steel back rib (3) and the wooden I-beam (6) by bolts for hoisting the template (2).

4. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 3, characterized in that: The hydraulic oil pipe (8) includes: Hydraulic oil pipe (18), centralized pump station (19), guide rail (15), upper reversing box (16) and lower reversing box (17); The guide rail (15) is fixedly arranged on the frame (1); The hydraulic oil pipe (18) adopts a double-acting piston cylinder. The cylinder diameter is determined according to the load calculation of the frame (1). The piston rod end is provided with a connecting ear plate.

5. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 4, characterized in that: The hydraulic oil pipe (18) is connected to a centralized pump station (19), and the centralized pump station (19) has a built-in high-pressure gear pump.

6. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 5, characterized in that: The guide rail (15) is provided with an upper reversing box (16) and a lower reversing box (17). The upper reversing box (16) and the lower reversing box (17) have built-in pawl mechanisms, which are respectively connected to the piston rod of the hydraulic oil pipe (18). The pawls inside the upper reversing box (16) and the lower reversing box (17) are adapted to the slots of the guide rail (15) for alternating locking and lifting of the guide rail (15) and the frame (1).

7. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 6, characterized in that: The frame (1) has an intelligent control system arranged in the middle layer, and the intelligent control system has a PLC main controller arranged inside, which is used to receive sensor data and output control commands.

8. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 7, characterized in that: The template (2) is equipped with an intelligent maintenance system, and the intelligent maintenance system is equipped with a fogging machine and a spraying system to increase the humidity of the maintenance environment.

9. The intelligent hydraulic climbing formwork construction technology for the main tower of a cable-stayed bridge according to claim 8, characterized in that: The plywood panel (7) is made of waterproof plywood with a thickness of ≥18mm; The back rib of the channel steel (3) is made of Q235 channel steel; The I-beam (6) is a solid wood square with a cross section of 100mm×100mm.

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