Pipe gallery forming and construction method using cast-in-place assembly mold

Abstract

The application discloses a comprehensive pipe gallery forming construction method using cast-in-situ assembling molds, relates to the technical field of pipe gallery construction, and comprises the following steps: excavating a foundation trench and reinforcing a foundation and a side slope, manufacturing a cushion layer of the foundation trench, installing a box-shaped outer mold, binding a bottom plate steel reinforcement cage, a side wall steel reinforcement cage and a middle partition wall steel reinforcement cage on the cushion layer, installing a bottom plate guide wall mold, pouring local bottom plate concrete and side wall concrete, removing the bottom plate guide wall mold, installing a bearing platform on the bottom plate, installing a moving platform on the bearing platform, transporting the box-shaped inner mold to a construction position by the moving platform and installing the box-shaped inner mold on the bottom plate concrete, binding a top plate steel reinforcement cage, pouring residual side wall concrete and middle partition wall concrete, then pouring top plate concrete, and removing the box-shaped inner mold and the box-shaped outer mold after maintenance is completed. The mold has stable structure and high strength, the inner side of the box-shaped outer mold is smooth, the joint precision is high, the smoothness of the attached waterproof coiled material is favorable, and the delivered finished pipe gallery is obviously improved in size standard and waterproof performance.

Description

Technical Field

[0001] This invention relates to the field of utility tunnel construction technology, specifically to a method for constructing and building an integrated utility tunnel using cast-in-place assembly molds. Background Technology

[0002] As urban infrastructure, underground utility tunnels have a huge potential market. However, domestic utility tunnel construction still generally adopts labor-intensive small formwork construction technology, which leads to slow project progress, poor finished product quality, high material consumption, high labor consumption, and often delays in construction due to a shortage of skilled workers.

[0003] The construction of municipal underground utility tunnels mainly uses scaffolding and bamboo plywood. This construction results in multiple formwork tie rods on the side walls of the tunnel, making formwork installation and removal inconvenient. At the same time, bamboo plywood construction cannot guarantee the surface flatness of the main structure, making it difficult to achieve a 100% tight seal when laying waterproof membrane later, which poses a risk of water seepage. Summary of the Invention

[0004] The purpose of this invention is to provide a method for constructing integrated utility tunnels using cast-in-place assembly molds, in order to solve the problems of inconvenient template installation and disassembly and low surface flatness of the constructed utility tunnels in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method for constructing a comprehensive utility tunnel using cast-in-place assembly molds, wherein the cast-in-place assembly molds include a box-shaped outer mold, a bottom slab guide wall mold, and a box-shaped inner mold, comprising the following steps: S1, excavating the foundation trench, reinforcing the foundation at the bottom of the trench, and installing sheet pile supports on both sides of the trench; S2, pouring C35 bottom sealing concrete on the foundation trench, using short-headed steel bars to control the elevation of the top surface of the sealing layer; S3, hoisting the box-shaped outer mold to the pre-embedded position on the sealing layer for fixed installation, with support rods provided between the tops of the box-shaped outer molds on both sides of the trench; S4, binding the bottom slab reinforcement cage, side wall reinforcement cage, and central partition wall reinforcement cage on the sealing layer, with the outer side of the side wall reinforcement cage abutting the inner side of the box-shaped outer mold, and the bottom slab reinforcement cage and... At the corners between the side wall reinforcement cages and at the corners between the bottom slab reinforcement cage and the middle partition wall reinforcement cage, install bottom slab guide wall formwork. Pour bottom slab concrete and side wall concrete. Pour the side wall concrete until it is flush with the top of the bottom slab guide wall formwork. After curing, remove the bottom slab guide wall formwork. S5. Install a foundation on the bottom slab concrete along the length of the foundation trench. Install a movable platform on the foundation that can move along it. Place the box-shaped inner formwork on the movable platform. The movable platform transports the box-shaped inner formwork to the construction position and installs it on the bottom slab concrete. The outer side of the box-shaped inner formwork fits against the inner side of the side wall concrete. S6. Tie the top slab reinforcement cage. Pour the remaining side wall concrete and middle partition wall concrete. Then pour the top slab concrete. After curing, remove the box-shaped inner formwork and box-shaped outer formwork.

[0006] Furthermore, the box-shaped outer mold is a rectangular box module covered with metal plates on both sides. One side serves as the outer mold for the side wall concrete and is covered with waterproof membrane. The other side is fitted with vertical ribs.

[0007] Furthermore, there is a detachable connection between two adjacent box-shaped outer molds located on the same side.

[0008] Furthermore, the outer side of the box-shaped outer mold is threaded with a lateral positioning screw that abuts against the sheet pile support.

[0009] Furthermore, the spacing between adjacent support rods along the length of the trench is 3000mm.

[0010] Furthermore, steel walers are fixedly connected to the sheet pile supports on both sides, and steel supports are fixedly connected between the two opposing steel walers.

[0011] Furthermore, the bottom plate guide wall mold includes a left box mold, a right box mold, and a telescopic connecting frame, with one end of the telescopic connecting frame connected to the left box mold and the other end connected to the right box mold.

[0012] Furthermore, the box-shaped inner mold includes a left inner mold, a right inner mold, and an adjusting connecting frame, with one end of the adjusting connecting frame connected to the left inner mold and the other end connected to the right inner mold.

[0013] Furthermore, there is a detachable connection between two adjacent box-shaped inner molds located on the same side.

[0014] Furthermore, when the side wall reinforcement cage is completed, the wall pre-embedded channel needs to be installed.

[0015] Compared with existing technologies, the integrated utility tunnel forming and construction method using cast-in-place assembly molds provided by this invention features a stable and high-strength mold structure with a high limit on reusability. After the box-shaped outer mold is fixed and positioned, a stable and robust semi-enclosed steel structure construction chamber is formed, which is sufficient to withstand the lateral pressure of soil at a height of more than 10 meters without deformation. Furthermore, the modeling method using cast-in-place assembly molds is standardized and efficient, significantly improving the overall construction progress. The flat inner side of the box-shaped outer mold and the high precision of the joints facilitate the smooth attachment of waterproof membrane, resulting in a significant improvement in the dimensional standards and waterproof performance of the delivered finished utility tunnel. The inclusion of a mobile platform greatly facilitates the installation and dismantling of the box-shaped inner mold. Attached Figure Description

[0016] To provide a clearer description of the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the embodiments will be briefly introduced below.

[0017] Figure 1 This is a structural diagram illustrating the construction of the base plate guide wall formwork provided in the embodiment. Figure 2This is a structural diagram of the completed main structure of the utility tunnel provided in the embodiment. Figure 3 The flowchart illustrates the integrated utility tunnel forming and construction method provided in this embodiment.

[0018] Explanation of reference numerals in the attached drawings: 1. Box-type outer mold; 2. Left box mold; 3. Right box mold; 4. Telescopic connecting frame; 5. Left inner mold; 6. Right inner mold; 7. Adjustable connecting frame; 8. Steel sheet pile support; 9. Lateral positioning screw; 10. Support rod; 11. Right-angle corbel; 12. Steel waler; 13. Steel support; 14. Subbase; 15. Main body of the pipe gallery; 16. Mobile platform. Detailed Implementation

[0019] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0020] Please see Figures 1-2 The cast-in-place assembly formwork includes a box-shaped outer formwork 1, a bottom plate guide wall formwork, and a box-shaped inner formwork. The box-shaped outer formwork 1 is a rectangular box module covered with metal plates on both sides. One side serves as the outer formwork for the side wall concrete and is covered with a waterproof membrane, while the other side is fitted with vertical ribs. Adjacent box-shaped outer formwork 1s on the same side are detachably connected, such as by bolts, with a connection point every 500mm longitudinally between adjacent box-shaped outer formwork 1s on the same side. The bottom plate guide wall formwork includes a left box formwork 2, a right box formwork 3, and a telescopic connecting frame 4. One end of the telescopic connecting frame 4 is connected to the left box formwork 2, and the other end is connected to the right box formwork 3. The telescopic connecting frame 4 is telescopic, allowing adjustment of the distance between the left box formwork 2 and the right box formwork 3 to accommodate the width between the side walls and the central partition wall of the main pipe gallery 15. The height difference of the planar splicing joint between adjacent left box formwork 2s or adjacent right box formwork 3s should be controlled within 0.5mm. The box-shaped inner mold includes a left inner mold 5, a right inner mold 6, and an adjusting connecting frame 7. One end of the adjusting connecting frame 7 is connected to the left inner mold 5, and the other end is connected to the right inner mold 6. The adjusting connecting frame 7 is telescopic, allowing adjustment of the distance between the left inner mold 5 and the right inner mold 6 to accommodate the width between the side walls and the central partition wall of the pipe gallery body 15. Adjacent left inner molds 5 or adjacent right inner molds 6 are detachably connected. A connection point is set every 500mm longitudinally between adjacent left inner molds 5, and the same applies to adjacent right inner molds 6.

[0021] See Figures 1-3This invention provides a method for constructing a comprehensive utility tunnel using cast-in-place precast molds. First, the foundation trench is excavated, and its dimensions, location, and slope stability are checked. The foundation at the bottom of the trench is reinforced. Steel sheet pile supports 8 are installed on both sides of the trench. Specifically, steel walers 12 are fixedly connected to the steel sheet pile supports 8 on both sides, and steel supports 13 are fixedly connected between two opposing steel walers 12. The incoming box-type outer mold 1, bottom guide wall mold, box-type inner mold, and facade waterproof membrane are inspected. The connecting bolts and positioning pins are tested for performance. Only after the inspection results are qualified and a report is issued can the equipment be used. After the foundation bearing capacity of the trench is accepted, a C35 sealing layer 14 concrete is poured on the foundation of the trench. The elevation measurement was accurate, and the elevation of the top surface of the foundation layer 14 was controlled using short-end steel bars. The accuracy was further verified during the concrete pouring process, and the surface of the foundation layer 14 was smooth. The box-shaped outer formwork 1 was lifted by a truck crane to its pre-embedded position within the foundation layer 14 for fixed installation. Lateral positioning screws 9 were threaded onto the outer side of the box-shaped outer formwork 1. These screws were tightened and pressed against the middle of the C-shaped steel on the outer side of the sheet pile support 8 or retaining pile, ensuring the box-shaped outer formwork 1 was installed firmly and securely, and guaranteeing that the net distance between the two box-shaped outer formworks 1 was equal to the outer diameter of the pipe gallery. Support rods 10 were installed between the tops of the box-shaped outer formwork 1 on both sides of the foundation trench to further stabilize the box-shaped outer formwork 1. Right-angle brackets 11 were provided between the support rods 10 and the corresponding box-shaped outer formwork 1. Adjacent support rods 10 were positioned along the length of the foundation trench. The spacing is 3000mm; adjacent outer molds on the same side are connected by connectors with a longitudinal spacing of 500mm. Each connector is rectangular and has two connection holes. Pins are inserted into the connection holes on the box-shaped outer mold 1. The bottom slab reinforcement cage, side wall reinforcement cage, and middle partition wall reinforcement cage are tied on the pad 14. The outer side of the side wall reinforcement cage is attached to the inner side of the box-shaped outer mold 1. The wall pre-embedded channel (not shown in the figure) is installed. One side of the pre-embedded channel is in close contact with the concrete contact surface of the bottom slab guide wall mold and the box-shaped inner mold. The bottom slab guide wall mold is installed at the corner between the bottom slab reinforcement cage and the side wall reinforcement cage, and at the corner between the bottom slab reinforcement cage and the middle partition wall reinforcement cage. The bottom slab concrete and the side wall concrete are poured. The side wall concrete is poured to the required depth. The bottom slab guide wall formwork is flush with the top of the formwork. During the pouring process, it is fully vibrated. After curing, the bottom slab guide wall formwork is removed and the remaining side wall reinforcement cage and the remaining central partition wall reinforcement cage are tied. The bottom slab leveling layer and drainage channel are constructed. The foundation is installed on the bottom slab concrete along the length of the trench. The foundation is made of 40 H-beams and square tubes. The foundation is parallel to the bottom slab of the pipe gallery. A movable platform 16 that can move along the foundation is installed on the foundation. The box-shaped inner formwork is placed on the movable platform 16. The movable platform 16 transports the box-shaped inner formwork to the construction position and installs it on the bottom slab concrete. The adjusting connecting frame 7 is a rectangular frame made of steel. The distance between the left inner formwork 5 and the right inner formwork 6 is adjusted. The outer side of the box-shaped inner formwork is attached to the inner side of the side wall concrete and the central partition wall concrete, respectively.After the box-shaped inner formwork is installed, the mobile platform 16 moves along the foundation to the next position to prepare for the installation of the next box-shaped inner formwork. After the box-shaped inner formwork is installed, vertical supports are added to the bottom to ensure the stability of the structure. After the box-shaped inner formwork is installed, the top slab reinforcement cage is tied and the top formwork is installed. The remaining side wall concrete and central partition wall concrete are poured, followed by the top slab concrete, which is fully vibrated during the pouring process. After the concrete is poured, it should be kept moist and cured in a timely manner. Moisturizing and curing can be done by sprinkling water, covering, or spraying curing agents. The curing method is to cover it with plastic film. It should be covered after the concrete is smoothed and finished. The plastic film should be tightly attached to the exposed concrete surface, and condensation should be kept inside the plastic film. Before the concrete strength reaches 1.2 N / mm2, no one should step on it or pile loads on it. Since it is waterproof concrete, the curing time should not be less than 14 days. After curing, the box-shaped inner formwork is removed and the formed pipe gallery main body 15 is transported out by the mobile platform 16.

[0022] The integrated utility tunnel forming and construction method using cast-in-place assembly molds provided by this invention features a stable and high-strength mold structure with a high limit on reusability. After the box-shaped outer mold 1 is fixed in place, a stable and robust semi-enclosed steel structure construction chamber is formed, which is sufficient to withstand the lateral pressure of soil at a height of more than 10 meters without deformation. Furthermore, the modeling method using cast-in-place assembly molds is standardized and efficient, significantly improving the overall construction progress. The inner side of the box-shaped outer mold 1 is flat with high joint precision, which facilitates the smooth attachment of waterproof membrane, resulting in a significant improvement in the dimensional standards and waterproof performance of the delivered finished utility tunnel. Moreover, the addition of a mobile platform 16 greatly facilitates the installation and dismantling of the box-shaped inner mold.

[0023] The foregoing description of certain exemplary embodiments of the present invention should not be construed as limiting the scope of protection of the claims. Those skilled in the art will recognize that the described embodiments can be modified in other ways without departing from the spirit and scope of the invention.

Claims

1. A method for constructing a comprehensive utility tunnel using cast-in-place assembly molds, wherein the cast-in-place assembly molds include a box-shaped outer mold (1), a bottom plate guide wall mold, and a box-shaped inner mold, characterized in that, Includes the following steps: S1. Excavation of the foundation trench, reinforcement of the foundation at the bottom of the foundation trench, and installation of steel sheet pile support on both sides of the foundation trench (8). S2. Pour C35 sealing layer (14) concrete on the foundation trench, and control the top elevation of the layer (14) with short-head steel bars; S3. The box-shaped outer mold (1) is hoisted to the pre-embedded position of the cushion layer (14) for fixed installation. Support rods (10) are provided between the tops of the box-shaped outer mold (1) on both sides of the foundation trench. S4. Tie the bottom plate reinforcement cage, side wall reinforcement cage and middle partition wall reinforcement cage on the cushion layer (14). The outer side of the side wall reinforcement cage is attached to the inner side of the box-shaped outer formwork (1). Install the bottom plate guide wall formwork at the corner between the bottom plate reinforcement cage and the side wall reinforcement cage and the corner between the bottom plate reinforcement cage and the middle partition wall reinforcement cage respectively. Pour the bottom plate concrete and the side wall concrete. Pour the side wall concrete to be flush with the top of the bottom plate guide wall formwork. Remove the bottom plate guide wall formwork after curing. S5. Install a foundation on the concrete base slab along the length of the trench. A movable platform (16) that can move along the foundation is installed on the foundation. The box-shaped inner mold is placed on the movable platform (16). The movable platform (16) transports the box-shaped inner mold to the construction position and installs it on the concrete base slab. The outer side of the box-shaped inner mold is in contact with the inner side of the side wall concrete. S6. Tie the top slab reinforcement cage, pour the remaining side wall concrete and middle partition wall concrete, then pour the top slab concrete, and remove the box-shaped inner formwork and box-shaped outer formwork after curing (1).

2. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, The box-shaped outer mold (1) is a rectangular box module covered with metal plates on both sides. One side serves as the outer mold for the side wall concrete and is covered with waterproof membrane on the surface. The other side is equipped with vertical ribs.

3. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, The two adjacent box-shaped outer molds (1) located on the same side are detachably connected.

4. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, The outer side of the box-shaped outer mold (1) is threaded with a lateral positioning screw (9) that abuts against the sheet pile support (8).

5. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, The spacing between adjacent support rods (10) along the length of the trench is 3000 mm.

6. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, Steel walers (12) are fixedly connected to the sheet pile supports (8) on both sides, and steel supports (13) are fixedly connected between the two opposite steel walers (12).

7. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, The bottom plate guide wall mold includes a left box mold (2), a right box mold (3) and a telescopic connecting frame (4). One end of the telescopic connecting frame (4) is connected to the left box mold (2), and the other end is connected to the right box mold (3).

8. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, The box-shaped inner mold includes a left inner mold (5), a right inner mold (6) and an adjustment connecting frame (7). One end of the adjustment connecting frame (7) is connected to the left inner mold (5), and the other end is connected to the right inner mold (6).

9. The method for constructing and molding an integrated utility tunnel according to claim 1, characterized in that, The inner molds of two adjacent box-type molds located on the same side are detachably connected.

10. The method for constructing and forming an integrated utility tunnel according to claim 1, characterized in that, When the side wall reinforcement cage is completed, the wall pre-embedded channel needs to be installed.

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