Anchoring cable tray assembly and method of shoring

Abstract

The present application relates to the technical field of engineering support, and provides an anchor rod cable tray assembly and a supporting method thereof. An anchor rod of a tray component is arranged in a tray body. A shaping component includes a shaping disc, a shaping pile, a constraint ring and a concrete bag. The shaping disc is arranged on the tray body, and a disc body of the shaping disc is provided with a central through hole for the anchor rod to pass through. The shaping pile is arranged on an upper surface of the shaping disc. The constraint ring is arranged around one or more shaping piles on the shaping disc, and forms an accommodating cavity together with the shaping disc. The interior of the concrete bag is filled with a plastic hardening material, and the concrete bag is arranged in the accommodating cavity. When a pre-tightening force is applied to the tray body by the anchor rod, the tray body extrudes the shaping disc, which in turn extrudes the concrete bag, so that the plastic hardening material in the concrete bag is shaped under pressure to fill the accommodating cavity and adhere to the uneven bedrock surface. After hardening, a high-strength bearing structure is formed, which can adapt to the undulations of the bedrock surface, eliminate stress concentration, and improve the overall bearing efficiency and long-term durability of the anchor rod support system.

Description

Technical Field

[0001] This invention relates to the field of engineering support technology, and in particular to an anchor cable tray assembly and its support method. Background Technology

[0002] Anchor bolt (cable) support technology is a key means of controlling surrounding rock deformation and maintaining the stability of engineering structures in modern geotechnical engineering. Its core mechanism is to connect deep stable rock mass with surface unstable rock mass through anchor bolts (cables), and transfer the prestress and working load applied by the anchor bolts (cables) to the rock mass surface through the support plate, thereby forming an effective load-bearing structure.

[0003] However, in actual engineering projects, due to multiple factors such as drilling and blasting excavation, mechanical tunneling, original joints and fissures in the rock mass, and unloading rebound, the resulting bedrock (or tunnel wall, slope) surface usually exhibits a significantly uneven state, making it difficult to form an ideal smooth loading surface. This is fundamentally contradictory to the currently widely used standardized anchor cable tray structure.

[0004] Currently, the mainstream anchor cable trays used in engineering (including arched trays, flat trays, and combinations thereof) are typically made of rigid metal sheets through stamping or casting. The bottom bearing surface of these trays is usually designed as a continuous flat surface or a flat surface with a central arch. When this flat bottom surface is directly installed on an uneven bedrock surface, the two can only make contact at a few protruding points or in local areas, while gaps of varying sizes are formed in the recessed areas.

[0005] Under the preload of the anchor bolts and subsequent rock mass loads, the load can only be transferred through limited contact points / areas. This causes these local contact areas to bear compressive stress far exceeding the material's design strength, resulting in severe stress concentration. Under long-term, repeated loading, the support plate is highly susceptible to plastic deformation, buckling, or even tearing at these stress concentration points, leading to premature failure. More seriously, the support plate cannot fully perform its load transfer function, resulting in poor overall support effectiveness of the anchor bolt support system. This could even trigger local rock mass instability, collapse, and other safety hazards, threatening the safety of construction and operation. Summary of the Invention

[0006] This invention provides an anchor cable tray assembly and its support method to address the aforementioned technical deficiencies in the prior art. It is a device that can adapt to the undulations of the bedrock surface and construct a high-strength, uniformly stressed transition layer between the tray and the bedrock, thereby optimizing the load transfer path, eliminating stress concentration, and improving the overall load-bearing capacity and long-term durability of the anchor (cable) support system.

[0007] A first aspect of the present invention provides an anchor cable tray assembly, comprising: A pallet component includes a pallet body and an anchor bolt, wherein the anchor bolt passes through the pallet body; Shaping components, including: A shaping disc is provided on the tray body, and the disc body of the shaping disc has a central through hole for the anchor rod to pass through; A shaping pile is provided on the upper surface of the shaping disc; A constraint ring surrounds one or more of the shaping posts disposed on the shaping disk and forms a receiving cavity with the shaping disk; A concrete bag, filled with a plastic hardening material, is placed inside the receiving cavity; When the anchor bolts apply a pre-tightening force to the pallet body, the pallet body squeezes the shaping disc, which in turn squeezes the concrete bag, causing the plastic hardening material inside the concrete bag to be shaped under pressure to fill the cavity and fit against the uneven bedrock surface, forming a high-strength load-bearing structure after hardening.

[0008] According to the anchor cable tray assembly provided by the present invention, the shaped piles are arranged in a circular array with the central through hole of the shaped plate as the center, and the shaped piles are perpendicular to the shaped plate.

[0009] According to the anchor cable tray assembly provided by the present invention, the shape of the shaped disc is adapted to the shape of the tray body, and the shaped pile is cylindrical; Both the shaping disc and the shaping post are made of metal, and the shaping post is welded and fixed to the surface of the shaping disc.

[0010] According to the anchor cable tray assembly provided by the present invention, the diameter of the shaped pile is 8 mm to 12 mm, and the height of the shaped pile is 20 mm to 30 mm; The spacing between two adjacent shaped piles is 30 mm to 50 mm.

[0011] According to the anchor cable tray assembly provided by the present invention, the constraint ring is a tough metal ring band, the thickness of the constraint ring is 2 mm to 3 mm, and the width of the constraint ring is 30 mm to 40 mm.

[0012] According to the anchor cable tray assembly provided by the present invention, one end of the constraint ring is provided with a first buckle, and the other end of the constraint ring is provided with a second buckle. The first buckle and the second buckle cooperate with each other to lock and fix the constraint ring after it is adjusted to the target shape around the shaping pile.

[0013] According to the anchor cable tray assembly provided by the present invention, the concrete bag body is made of geotextile with high strength and a specified permeability coefficient, and the plastic hardening material filled inside the concrete bag is high-strength fiber concrete.

[0014] According to the anchor cable tray assembly provided by the present invention, the total volume of the concrete bag after being filled with plastic hardening material is greater than the volume of the receiving cavity formed by the shaping disc and the constraint ring.

[0015] A second aspect of the present invention provides a method for supporting an anchor cable tray assembly as described in any of the preceding claims, comprising the following steps: The shaping disc is placed on the bedrock surface to be supported, and the constraint ring is wrapped around one or more shaping piles on the shaping disc according to the convex and concave contour of the bedrock surface. The shape of the constraint ring is adjusted to form a receiving cavity that matches the contour of the bedrock surface. The concrete bag filled with plastic hardening material is placed in the receiving cavity, and the anchor rod is passed through the tray body, the central through hole of the shaping plate and the concrete bag in sequence, and anchored in the bedrock; Adjust the nut at the end of the anchor rod to apply a preload to the tray body. The tray body squeezes the shaping disc, which in turn squeezes the concrete bag, forcing the plastic hardening material inside the concrete bag to undergo plastic deformation, filling the cavity and tightly fitting the uneven bedrock surface. After extrusion molding is completed, the plastic hardening material inside the concrete bag is cured until it is completely hardened, forming a high-strength load-bearing body that is tightly attached to the bedrock surface and has a flat top.

[0016] The support method of the anchor cable tray assembly provided by the present invention further includes: when the plastic hardening material is under pressure, its front end portion protrudes from the constraint ring and fits into the recessed portion of the bedrock surface.

[0017] The anchor cable tray assembly provided by the present invention, by setting a shaping component between the tray component and the bedrock, when the anchor of the tray component applies a pre-tightening force to the tray body, the tray body squeezes the shaping disc of the shaping component, and the shaping disc then squeezes the concrete bag, so that the plastic hardening material in the concrete bag is compressed and shaped to fill the cavity and fit into the uneven bedrock surface, forming a high-strength load-bearing structure after hardening.

[0018] By forming a high-strength concrete transition layer that is completely integrated with the bedrock, traditional point or line loads are transformed into surface loads, ensuring that the pallet body and the molded tray always act on a flat and solid base. This avoids early failure of the pallet due to local stress exceeding its yield strength, such as buckling and tearing, allowing the pallet to perform its designed load-bearing capacity stably and for a long time.

[0019] Furthermore, the adaptive nature of the anchor cable tray assembly provided by this invention is proactive, involving a dynamic filling process completed under load. This ensures that regardless of the irregularity of the bedrock surface, a seamless, tight contact is ultimately achieved, eliminating all safety hazards caused by poor contact, optimizing the load transfer path, and improving the overall reliability of the support system. Due to the presence of the high-strength concrete transition layer, the preload and working load of the anchor bolts can be evenly and smoothly distributed across a wider area of ​​the rock mass. This not only improves the immediate effectiveness of the support but also enhances the long-term stability and safety reserve of the support system by improving the stress state of the surrounding rock, which is crucial for controlling rock mass deformation.

[0020] Furthermore, the support method for the anchor cable tray assembly provided by this invention is fully integrated into the existing anchor bolt construction process, namely drilling, hole cleaning, anchor bolt installation, wire mesh / steel strip installation, installation of this assembly and tray, and tightening of nuts. No special equipment or complex processes are required; only two simple steps are added: assembling the molded component and filling the concrete bag. This is easy for on-site workers to master and has good prospects for engineering application. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the support structure of the anchor cable tray assembly provided in an embodiment of the present invention.

[0023] Figure 2 yes Figure 1 A cross-sectional view of the support structure of the anchor cable tray assembly shown.

[0024] Figure 3 This is a schematic diagram of the structure of the shaping component in the anchor cable tray assembly provided by the present invention.

[0025] Figure 4 This is a schematic diagram of the structure of the shaping disc and constraint ring in the anchor cable tray assembly provided by the present invention.

[0026] Figure 5 yes Figure 4 Enlarged view of part A in the middle.

[0027] Figure 6 This is a schematic diagram of the initial support structure of the anchor cable tray assembly provided in an embodiment of the present invention.

[0028] Figure label: 10. Pallet components; 11. Pallet body; 12. Anchor bolts; 20. Shaping component; 21. Shaping disc; 211. Central through hole; 22. Shaping post; 23. Restraining ring; 231. First buckle; 232. Second buckle; 24. Concrete bag; 25. Receiving cavity; 30. Bedrock. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0030] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application based on the specific circumstances.

[0031] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0032] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the embodiments of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0033] Figure 1 This is a schematic diagram of the support structure of the anchor cable tray assembly provided in an embodiment of the present invention. Figure 2 yes Figure 1 A cross-sectional view of the support structure of the anchor cable tray assembly shown. Figure 3 This is a schematic diagram of the structure of the shaping component in the anchor cable tray assembly provided by the present invention. Figure 4 This is a schematic diagram of the structure of the shaping disc and constraint ring in the anchor cable tray assembly provided by the present invention. Figure 5 yes Figure 4 Enlarged view of part A in the middle.

[0034] See Figures 1 to 5 This invention provides an anchor cable tray assembly, which includes a tray component 10 and a shaping component 20.

[0035] The pallet component 10 includes a pallet body 11 and anchor bolts 12. The pallet body 11 is an arched or flat pallet made of conventional metal (such as Q235 steel). The pallet body 11 is a standard component of the anchor bolt 12 support system, used as a rigid platform for applying and bearing loads in the final state. The anchor bolts 12 are inserted through the center of the pallet body 11 and are the core component providing active support force. Nuts are fitted on the anchor bolts 12, and a preload is applied by tightening the nuts, transferring the rock mass load to the pallet.

[0036] The shaping component 20 includes a shaping disc 21, shaping posts 22, a restraining ring 23, and a concrete bag 24. The shaping disc 21 is disposed on the tray body 11, and the center of the disc 21 has a central through hole 211 for the anchor rod 12 to pass through. The shaping posts 22 are disposed on the upper surface of the shaping disc 21 and are fixedly connected to the shaping disc 21. The restraining ring 23 surrounds one or more shaping posts 22 disposed on the shaping disc 21 and forms a receiving cavity 25 with the shaping disc 21, in which the concrete bag 24 is located.

[0037] The shaped disc 21 can be made of rigid metal (such as carbon structural steel) and processed by stamping to ensure that the disc has sufficient load-bearing rigidity to withstand the compressive load during the installation of the anchor bolt 12 without serious deformation. The shaped disc 21 is located between the tray body 11 and the bedrock 30 and serves as the load-bearing foundation and structural skeleton of the shaped component 20.

[0038] The shaping piles 22 are several columnar protrusions (such as cylinders) vertically fixed to the upper surface of the shaping disc 21. The shaping piles 22 serve as variable path points for the shape of the constraint ring 23. The perimeter and shape of the closed path formed by the constraint ring 23 as it passes around different numbers and combinations of shaping piles 22 will change. The constraint ring 23 can be pre-adjusted to roughly match the unevenness of the bedrock 30 by selecting the surrounding piles.

[0039] The constraint ring 23 is a flexible, bendable strip-shaped component (such as an elastic steel strip). One end can be fitted with an inner hook, and the other end with an outer hook. The inner and outer hooks can interlock to form a closed ring, serving as a variable boundary mold. Essentially, the constraint ring 23 and the shaping disc 21 together enclose a receiving cavity 25 that is open at the top and closed at the bottom and sides. The shape and size of the receiving cavity 25 can be flexibly adjusted by surrounding different shaping piles 22, thus pre-setting a forming space for the concrete bag 24 that conforms to the macroscopic contour of the bedrock 30. When the concrete bag 24 is compressed and shaped, the sidewalls of the constraint ring 23 restrict excessive radial flow of concrete, forcing the concrete to primarily flow downwards (towards the bedrock 30) and fill the gaps within the receiving cavity 25, ensuring controllable forming.

[0040] The concrete bag 24 is made of a high-strength, wear-resistant, and permeable flexible fabric (such as polypropylene geotextile), filled with uncured, high-strength fiber-reinforced concrete or other plastic hardening materials with fluid plasticity. Initially, the bag acts as a container for the plastic material. Under pressure, the material inside the bag is fluid, penetrating and tightly adhering to the micro and macroscopic pits on the surface of the bedrock 30. After hardening, the material, together with the concrete bag 24, forms a high-strength solid filler block that is completely complementary to the geometry of the bedrock 30 surface. This block is used to transfer the uniformly distributed load from the shaping disc 21 to the entire contact surface of the bedrock 30 without stress concentration through its own cured solid form.

[0041] Based on the above structural description, the assembly process of the molding component 20 provided in the embodiment of the present invention will be explained below: Before assembly, the surface of bedrock 30 is surveyed, and a constraint ring 23 of appropriate height is selected according to the unevenness of bedrock 30.

[0042] Then, the restraint ring 23 is wrapped around the selected multiple shaping piles 22, bent into a shape that closely resembles the undulation trend of the rock surface, and fixed with its locking hook. At this time, a pre-shaped receiving cavity 25 is formed on the shaping disc 21.

[0043] The concrete bag 24, filled with uncured high-strength fiber reinforced concrete, is placed into the receiving cavity 25, so that the volume of the concrete bag 24 is slightly larger than that of the receiving cavity 25, resulting in a slightly inflated state. At this point, the assembly of the shaped component 20 is complete.

[0044] Finally, the assembled molding component 20 (molding disc 21, restraint ring 23, and concrete bag 24) is placed on the bedrock 30 at the anchor bolt 12 hole, and the anchor bolt 12 is inserted. Then, the tray body 11 and nut are installed, and the nut is tightened with a torque wrench. At this point, the crucial adaptive process begins: the nut applies a compressive force F to the molding disc 21 through the tray body 11. The molding disc 21 transmits the force F to the filled concrete bag 24. The plastic concrete within the concrete bag 24 flows under pressure, guided in two directions: laterally, restricted by the restraint ring 23, allowing only limited expansion to completely fill the receiving cavity 25; and pressure forces the concrete to be squeezed out from the bottom opening of the restraint ring 23, surging in and completely filling all voids between the molding disc 21 and the surface of the bedrock 30.

[0045] This process continues until the concrete pressure inside the concrete bag 24 and the preload of the nut reach equilibrium, at which point the deformation of the concrete bag 24 stops. At this point, the lower surface of the concrete bag 24 is in close contact with the uneven bedrock surface 30, without any gaps. Maintain the preload and cure the concrete (usually for no less than 7 days) to allow it to set and reach its design strength (e.g., C60 or higher).

[0046] After the concrete hardens, the original shaped component 20 transforms into a rigid composite component: a high-strength concrete filler block (formed from the hardened contents of the concrete bag 24) is securely encased in a shape-matched mold formed by the shaped disc 21, the restraining ring 23, and the bedrock 30. At this point, an optimized load transfer path is formed: the rock mass load / anchor bolt 12 tension is transferred to the tray body 11, then to the shaped disc 21 (the flat, rigid surface), and subsequently to the high-strength concrete filler block and the bedrock 30 (full surface contact). This eliminates the point contact and stress concentration phenomena between the tray and the bedrock 30 in traditional technologies.

[0047] It is understood that the anchor cable tray assembly provided in this embodiment of the invention, by setting a shaping component 20 between the tray component 10 and the bedrock 30, when the anchor 12 of the tray component 10 applies a pre-tightening force to the tray body 11, the tray body 11 squeezes the shaping disc 21 of the shaping component 20, and the shaping disc 21 then squeezes the concrete bag 24, so that the plastic hardening material in the concrete bag 24 is compressed and shaped to fill the receiving cavity 25 and fit into the uneven bedrock 30 surface, forming a high-strength load-bearing structure after hardening.

[0048] By forming a high-strength concrete transition layer that is completely in contact with the bedrock 30, traditional point loads or line loads are transformed into surface loads, ensuring that the pallet body 11 and the shaped plate 21 always act on a flat and solid base. This avoids early failure of the pallet due to local stress exceeding its yield strength, such as buckling and tearing, allowing the pallet to perform its designed load-bearing capacity stably and for a long time.

[0049] Furthermore, the adaptive nature of the anchor cable tray assembly provided by this invention is proactive, involving a dynamic filling process completed under load. This ensures that regardless of the irregularity of the bedrock surface 30, a seamless and tight contact can ultimately be achieved, eliminating all safety hazards caused by poor contact, optimizing the load transfer path, and improving the overall reliability of the support system. Due to the presence of the high-strength concrete transition layer, the preload and working load of the anchor 12 can be evenly and smoothly distributed across a wider area of ​​the rock mass. This not only improves the immediate effectiveness of the support but also enhances the long-term stability and safety reserve of the support system by improving the stress state of the surrounding rock, which is crucial for controlling rock mass deformation.

[0050] Continue reading Figure 3 and Figure 4 In some embodiments of the present invention, the shaping piles 22 are arranged in a circular array with the central through hole 211 of the shaping disk 21 as the center, and the shaping piles 22 are perpendicular to the shaping disk 21.

[0051] Essentially, the shaped piles 22 are not randomly distributed on the shaped disc 21, but arranged at equal angles and radii around the anchor bolt 12 perforation (i.e., the force center). This ensures that when the constraint ring 23 circulates, regardless of which piles it chooses to surround, the resulting receiving cavity 25 is symmetrical or approximately symmetrical on the horizontal plane. This guarantees that when the concrete bag 24 is under pressure and shaped, the internal concrete is subjected to uniform radial constraint, and the pressure distribution flowing towards the bedrock 30 is more balanced, which is conducive to forming a stable and reliable force transmission body.

[0052] The shaped pile 22 is perpendicular to the shaped disc 21, meaning the pile axis forms a 90-degree angle with the upper surface (i.e., the bearing surface) of the shaped disc 21. This provides a standard and consistent positioning reference for the restraint ring 23. The vertical pile allows the inner surface of the restraint ring 23 to remain parallel or tangential to the side of the pile during encirclement, facilitating smooth bending, positioning, and locking of the restraint ring 23. It also ensures that the sidewall formed by the restraint ring 23 is perpendicular or approximately perpendicular to the shaped disc 21, thereby enclosing a regular receiving cavity 25, which is beneficial for the filling and stress distribution of the concrete bag 24.

[0053] This design makes the adjustment of the shape of the constraint ring 23 more systematic. On-site construction personnel can quickly and intuitively select the shaping piles 22 to be surrounded based on the undulation direction of the bedrock 30. For example, if the bedrock 30 is deeply recessed in a certain direction, several adjacent piles in that direction can be selected to expand the size of the cavity 25 in that direction. For example, 6, 8 or 10 shaping piles 22 can be surrounded to form different shapes such as circles, ellipses or irregular polygons of the constraint ring 23 to match the convex and concave contours of the bedrock 30 surface, thereby improving the efficiency and controllability of on-site construction and avoiding arbitrariness.

[0054] Continue reading Figure 1 and Figure 2 In some embodiments of the present invention, the shape of the shaping tray 21 is adapted to the shape of the tray body 11, that is, the planar outline shape of the shaping tray 21 (such as circular, square, rectangular, etc.) is consistent with or slightly smaller than the standard tray body 11 above it. This ensures that the pressure applied by the tray body 11 can be completely and without omission transmitted through the shaping tray 21, avoiding pressure suspension or uneven loading. For example, if the tray is square, the shaping tray 21 is also preferably square.

[0055] The shaped pile 22 is cylindrical, and the cylindrical shape is a symmetrical structure without sharp edges. This not only facilitates a smooth transition when the restraining ring 23 is wound around it, reducing wear and stress concentration on the restraining ring 23, but also, when the concrete bag 24 is compressed and the concrete laterally squeezes the restraining ring 23, the pressure distribution of the cylindrical pile body on the inner side of the restraining ring 23 is more uniform, making it less likely to cause local buckling of the restraining ring 23.

[0056] Both the shaping disc 21 and the shaping pile 22 are made of metal, such as Q235 carbon steel, to ensure that the shaping disc 21 and the pile have sufficient strength and rigidity, and will not undergo plastic deformation or failure when subjected to the pre-tightening force of the anchor rod 12 and subsequent rock mass loads. The shaping pile 22 is welded and fixed to the surface of the shaping disc 21 to ensure that the shaping pile 22 will not loosen or fall off the shaping disc 21 during construction (such as when the restraint ring 23 is wrapped around it or when the concrete bag 24 is squeezed) and during long-term service, thereby ensuring the integrity and reliability of the entire shaping component 20 foundation skeleton.

[0057] In some embodiments of the present invention, the diameter of the shaped pile 22 is 8 to 12 mm to ensure that the shaped pile 22 has sufficient bending and shear strength to resist the force generated by the restraint ring 23 and the lateral pressure of the concrete when it is surrounded. If the diameter is too small, it will be easily bent, and if it is too large, it will waste materials and occupy space.

[0058] The height of the shaped pile 22 is 20 to 30 mm, providing sufficient vertical space so that the height of the enclosure formed by the restraint ring 23 when it surrounds different piles is sufficient to accommodate and restrain the concrete bag 24. If the height is too low, the restraint effect will be poor, and the concrete will easily overflow from the top; if it is too high, it is unnecessary and increases cost and weight.

[0059] The spacing between two adjacent shaped piles 22 is 30 to 50 mm. If the spacing is too small, there will be too many shaped piles 22, making adjustment too cumbersome; if the spacing is too large, the adjustment flexibility will be poor, making it difficult to precisely adapt to the contours of the rock surface. This spacing range provides sufficient adjustment flexibility while also ensuring the overall strength of the shaped disc 21.

[0060] In some embodiments of the present invention, the constraint ring 23 is a metal ring with elastic recovery properties, preferably spring steel, possessing good plastic deformation capacity and elastic recovery performance, and its bending shape can be adjusted multiple times according to the surface morphology of the bedrock. After undergoing a certain degree of bending plastic deformation, it still has the tendency or ability to return to its original shape. At the same time, during on-site construction, operators can manually bend the ring to adapt to the shaped pile 22; after bending and shaping, the ring itself has a certain shape retention force and is not easily loosened or deformed by the slight lateral pressure of the concrete bag 24.

[0061] The thickness of the restraint ring 23 is 2 to 3 mm, and the width of the restraint ring 23 is 30 to 40 mm. These two parameters together determine the stiffness of the restraint ring 23. This thickness range ensures that the ring has sufficient stiffness to restrain the lateral pressure of the concrete, while also being able to be bent artificially. This width range is sufficient to accommodate the concrete bag 24 in its initial state and ensures that when the concrete is compressed and deformed, with the front end protruding, there is still a sufficient height of the sidewall to maintain restraint on the upper concrete, preventing it from being excessively squeezed out from the side.

[0062] Continue reading Figure 5 In some embodiments of the present invention, one end of the constraint ring 23 is provided with a first buckle 231 and the other end of the constraint ring 23 is provided with a second buckle 232. The first buckle 231 and the second buckle 232 cooperate with each other to lock and fix the constraint ring 23 after it is adjusted to the target shape around the shaping pile 22.

[0063] The first snap fastener 231 and the second snap fastener 232 are mutually cooperating hook-shaped, hole-shaped, or convex-concave structures, such as the inner hook and outer hook provided above. The first snap fastener 231 and the second snap fastener 232 can be connected by overlapping, hooking, or snapping. After adjusting the shape of the constraint ring 23, locking the two end snap fasteners can quickly fix its shape, preventing the constraint ring 23 from loosening due to accidental force during subsequent operations such as placing the concrete bag 24 and installing the anchor rod 12, which would cause the shape of the preset receiving cavity 25 to change. This provides a quick, tool-free, detachable connection solution, simplifies on-site installation steps, improves construction efficiency, and ensures the preset accuracy of the shape of the receiving cavity 25.

[0064] Figure 6 This is a schematic diagram of the initial support structure of the anchor cable tray assembly provided in an embodiment of the present invention.

[0065] See Figure 6In some embodiments of the present invention, the concrete bag 24 is made of geotextile with high strength and a specified permeability coefficient, ensuring that the bag will not rupture during concrete filling, handling, placement, and compression molding. The specified permeability coefficient means that the fabric allows water to slowly seep out under certain pressure, but does not allow cement particles to pass through. This facilitates the removal of excess water from the concrete during curing, promoting concrete setting, hardening, and strength gain, while also preventing cement paste loss, thus ensuring the final strength and quality of the concrete.

[0066] For example, concrete bag 24 is made of polypropylene geotextile, with a warp and weft tensile strength of not less than 15 kN / m and a permeability coefficient not greater than 1×10⁻⁶. -3 With a strength of cm / s, it possesses high strength, wear resistance, and a certain degree of permeability. It can withstand the weight and compressive force of concrete after mixing and can drain excess water during the concrete curing process, ensuring the development of concrete strength.

[0067] The plastic hardening material filled in the concrete bag 24 is high-strength fiber-reinforced concrete. If the concrete's design strength grade is not lower than C60, it contains 0.8%-1.2% by volume of basalt fiber or polypropylene fiber to improve the concrete's crack resistance and toughness, ensuring the final strength of the load-bearing structure after hardening. The fibers form a three-dimensional randomized support network within the concrete, which can suppress plastic shrinkage and micro-cracks after hardening, thus improving its crack resistance, toughness, and durability. This is crucial for support structures subjected to dynamic loads and uneven settlement.

[0068] In some embodiments of the present invention, the total volume of the concrete bag 24 after being filled with the plastic hardening material is greater than the volume of the receiving cavity 25 formed by the shaping disc 21 and the restraining ring 23. Typically, it exceeds the volume of the receiving cavity 25 by 10% to 15%, ensuring that the concrete can fully fill the cavity and protrude from the restraining ring during subsequent extrusion, thus adhering tightly to the bedrock surface.

[0069] Essentially, the concrete bag 24 is overfilled, and when placed into the receiving cavity 25, it is in a slightly full, pre-tightly fitted initial state against the inner wall of the restraint ring 23. This ensures that when the pre-tightening force is applied, the concrete within the bag 24 immediately receives sufficient lateral restraint and generates downward compressive force, forcing the concrete to flow quickly and effectively to fill all depressions on the surface of the bedrock 30. If underfilled, the concrete may not be able to completely fill deep voids, resulting in internal defects.

[0070] Continue reading Figure 1 and Figure 6 The present invention also provides a support method based on the anchor cable tray assembly provided in any of the above embodiments, comprising the following steps: The shaping disc 21 is placed on the surface of the bedrock 30 to be supported, and the restraining ring 23 is wrapped around one or more shaping piles 22 on the shaping disc 21 according to the convex and concave contour of the bedrock 30 surface. The shape of the restraining ring 23 is adjusted to form a receiving cavity 25 that matches the contour of the bedrock 30 surface. A concrete bag 24 filled with plastic hardening material is placed in the receiving cavity 25, and the anchor rod 12 is passed through the central through hole 211 of the tray body 11, the plastic plate 21, and the concrete bag 24 in sequence, and anchored in the bedrock 30. Adjust the nut at the end of the anchor rod 12 to apply a pre-tightening force to the pallet body 11. The pallet body 11 squeezes the shaping disc 21, and then squeezes the concrete bag 24, forcing the plastic hardening material in the concrete bag 24 to undergo plastic deformation, fill the receiving cavity 25 and fit tightly against the uneven bedrock 30 surface. After extrusion molding is completed, the plastic hardening material inside the concrete bag 24 is cured until it is completely hardened, forming a high-strength load-bearing body that is tightly attached to the surface of the bedrock 30 and has a flat top.

[0071] The support method of the anchor cable tray assembly also includes: when the plastic hardening material is under pressure, its front end protrudes from the restraint ring 23 and fits into the recessed part of the bedrock 30 surface.

[0072] Specifically, the support method for the anchor cable tray assembly includes the following steps: First, the surface of the bedrock 30 at the construction site is surveyed, and the unevenness of the bedrock 30 surface (such as the maximum difference in height between protrusions and depressions) is measured. Based on the measurement results, a constraint ring 23 with the corresponding height specification is selected. At the same time, the shaping plate 21, the shaping pile 22 (pre-installed in the shaping plate 21), the concrete bag 24 and the high-strength fiber concrete raw materials are prepared.

[0073] Mix the high-strength fiber concrete according to the design ratio, and the mixing time shall not be less than 3 minutes to ensure that the fiber is evenly dispersed in the concrete and there is no clumping. After mixing, slowly fill the concrete into the concrete bag 24. During the filling process, gently tap the bag to expel internal air bubbles. After filling to the preset volume, seal the mouth of the concrete bag 24.

[0074] Then, the shaping disc 21 is placed at the designated position on the surface of the bedrock 30 to be supported (coaxial with the anchor bolt 12 hole). According to the convex and concave contour of the bedrock 30 surface, the number of shaping piles 22 that the restraining ring 23 needs to surround is determined. The restraining ring 23 is fitted to the upper surface of the shaping disc 21 and surrounds the designated shaping piles 22. The bending shape of the restraining ring 23 is adjusted so that the outer contour of the restraining ring 23 matches the convex and concave trend of the bedrock 30 surface.

[0075] After the shape of the constraint ring 23 is adjusted to the correct position, the inner hooks and outer hooks at both ends of the ring are hooked together to form a closed lock, thus fixing the shape of the constraint ring 23 and completing the assembly of the constraint ring 23 and the shaping disc 21.

[0076] Then, the concrete bag 24 filled with high-strength fiber concrete is placed in the cavity formed by the shaping plate 21 and the restraint ring 23. Since the volume of the concrete bag 24 is larger than the volume of the cavity, the concrete bag 24 will naturally fit the inner wall of the restraint ring 23 and initially fill the cavity. At this time, the concrete is in a plastic state before final setting and has good shape adaptability.

[0077] Finally, one end of the anchor rod 12 is passed through the central through hole 211 of the molding plate 21, the concrete bag 24, and the anchor rod 12 hole on the bedrock 30. The anchor rod 12 is fixed inside the bedrock 30 according to the traditional anchor rod 12 installation method (such as grouting anchoring or mechanical anchoring). Then, a traditional anchor rod 12 cable tray is fitted onto the end of the anchor rod 12 located above the molding plate 21, and then the nut is screwed on. The nut is tightened to the designed preload (usually 100-200 N·m) using a torque wrench.

[0078] During the tightening of the nut, the nut squeezes the traditional tray, and the tray further squeezes the shaping disc 21. The shaping disc 21 transmits the extrusion force to the concrete bag 24. The concrete bag 24, which is in a plastic state, changes shape under the extrusion force, fully filling the cavity formed by the shaping disc 21 and the constraint ring 23, and the front end protrudes from the constraint ring 23, closely fitting the uneven parts of the bedrock 30 surface, forming a shape that is completely adapted to the bedrock 30 surface.

[0079] After extrusion molding is completed, the concrete bag 24 is cured for no less than 7 days (or the curing time is extended according to the concrete strength development requirements); during the curing process, the high-strength fiber concrete gradually sets and hardens, and its strength continues to increase, eventually forming a high-strength load-bearing structure that is in contact with the surface of the bedrock 30 and whose top is flush with the molding plate 21.

[0080] After the concrete bag 24 has completely solidified, the anchor cable tray assembly forms a complete force-bearing system consisting of bedrock 30, hardened concrete bag 24, shaped plate 21, traditional tray, and anchor 12. The traditional tray acts directly on the flat shaped plate 21. Subsequent rock loads and anchor 12 preload can be evenly transferred to the hardened concrete bag 24 through the shaped plate 21, and then smoothly transferred to the bedrock 30 by the concrete bag 24, avoiding stress concentration and achieving reliable support.

[0081] The support method provided in this invention avoids stress concentration when the existing planar pallet contacts the bedrock 30 by adaptively fitting the shaped component 20 to the uneven bedrock 30 and forming a flat stress interface after final setting. This prevents premature buckling failure of the pallet, fully utilizes the load transfer function of the pallet, and extends the service life of key components of the support structure. The constraint ring 23 is elastically shaped and its height can be selected on-site. It can adjust its shape around different shaped piles 22 on the shaped plate 21. Combined with the shape adaptation of the concrete bag 24 in its plastic state, the anchor cable pallet assembly can flexibly adapt to the uneven surface of the bedrock 30 after excavation, eliminating the potential gap between the support and the bedrock 30. The high-strength fiber concrete has high strength after final setting, and the flat interface formed allows the pallet load to be evenly transferred to the bedrock 30, optimizing the load transfer path, enhancing the overall bearing capacity of the anchor cable support structure, and ensuring the long-term stability and safety of the rock mass deformation control project. The anchor cable tray assembly can be used in conjunction with the traditional anchor 12 installation process, without the need for complex special equipment. The steps of filling the concrete bag 24, shaping the restraint ring 23, and tightening the anchor 12 are easy to operate, which facilitates on-site construction and promotion, and lowers the threshold for engineering application.

[0082] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An anchor cable tray assembly, characterized in that, include: A pallet component includes a pallet body and an anchor bolt, wherein the anchor bolt passes through the pallet body; Shaping components, including: A shaping disc is provided on the tray body, and the disc body of the shaping disc has a central through hole for the anchor rod to pass through; A shaping pile is provided on the upper surface of the shaping disc; A constraint ring surrounds one or more of the shaping posts disposed on the shaping disk and forms a receiving cavity with the shaping disk; A concrete bag, filled with a plastic hardening material, is placed inside the receiving cavity; When the anchor bolts apply a pre-tightening force to the pallet body, the pallet body squeezes the shaping disc, which in turn squeezes the concrete bag, causing the plastic hardening material inside the concrete bag to be shaped under pressure to fill the cavity and fit against the uneven bedrock surface, forming a high-strength load-bearing structure after hardening.

2. The anchor cable tray assembly according to claim 1, characterized in that, The shaped piles are arranged in a circular array with the central through hole of the shaped disc as the center, and the shaped piles are perpendicular to the shaped disc.

3. The anchor cable tray assembly according to claim 2, characterized in that, The shape of the shaping disc is adapted to the shape of the tray body, and the shaping post is cylindrical; Both the shaping disc and the shaping post are made of metal, and the shaping post is welded and fixed to the surface of the shaping disc.

4. The anchor cable tray assembly according to claim 2, characterized in that, The diameter of the shaped pile is 8mm to 12mm, and the height of the shaped pile is 20mm to 30mm; The spacing between two adjacent shaped piles is 30 mm to 50 mm.

5. The anchor cable tray assembly according to claim 1, characterized in that, The constraint ring is a tough metal ring with a thickness of 2 mm to 3 mm and a width of 30 mm to 40 mm.

6. The anchor cable tray assembly according to claim 5, characterized in that, One end of the constraint ring is provided with a first buckle, and the other end of the constraint ring is provided with a second buckle. The first buckle and the second buckle cooperate with each other to lock and fix the constraint ring after it is adjusted to the target shape around the shaping pile.

7. The anchor cable tray assembly according to any one of claims 1 to 6, characterized in that, The concrete bag is made of geotextile with high strength and a specified permeability coefficient, and the plastic hardening material filled inside the concrete bag is high-strength fiber concrete.

8. The anchor cable tray assembly according to claim 7, characterized in that, The total volume of the concrete bag after being filled with the plastic hardening material is greater than the volume of the receiving cavity formed by the shaping disc and the constraint ring.

9. A support method for an anchor cable tray assembly as described in any one of claims 1 to 8, characterized in that, Includes the following steps: The shaping disc is placed on the bedrock surface to be supported, and the constraint ring is wrapped around one or more shaping piles on the shaping disc according to the convex and concave contour of the bedrock surface. The shape of the constraint ring is adjusted to form a receiving cavity that matches the contour of the bedrock surface. The concrete bag filled with plastic hardening material is placed in the receiving cavity, and the anchor rod is passed through the tray body, the central through hole of the shaping plate and the concrete bag in sequence, and anchored in the bedrock; Adjust the nut at the end of the anchor rod to apply a preload to the tray body. The tray body squeezes the shaping disc, which in turn squeezes the concrete bag, forcing the plastic hardening material inside the concrete bag to undergo plastic deformation, filling the cavity and tightly fitting the uneven bedrock surface. After extrusion molding is completed, the plastic hardening material inside the concrete bag is cured until it is completely hardened, forming a high-strength load-bearing body that is tightly attached to the bedrock surface and has a flat top.

10. The support method for the anchor cable tray assembly according to claim 9, characterized in that, Also includes: When the plastic hardening material is under pressure, its front end protrudes from the constraint ring and fits into the recessed area on the bedrock surface.

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