Sandwiched steel pipe concrete tower and construction method and manufacturing tooling
By using a sandwich steel tube concrete tower construction method and tooling system, the problems of precision control, concrete compaction and prestress synergy in the manufacturing process have been solved, achieving high-quality, economical and efficient tower manufacturing, which is particularly suitable for large structures such as offshore wind power.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- HUADIAN (YANGJIANG YANGDONG) NEW ENERGY CO LTD
- Filing Date
- 2026-02-11
- Publication Date
- 2026-06-12
Smart Images
Figure CN122190557A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wind power generation technology, specifically to sandwiched steel pipe concrete towers, construction methods, and tower manufacturing tooling. Background Technology
[0002] As the development of clean energy sources such as offshore wind power continues to expand into deeper waters and onto larger scales, unprecedented demands are being placed on the load-bearing capacity, stability, durability, and economy of supporting tower structures. While traditional pure steel tower structures offer advantages such as light weight and rapid manufacturing and installation, they face significant bottlenecks, including a surge in steel consumption due to larger scale, high corrosion and maintenance costs, and poor economic efficiency. To address these challenges, the hollow-core steel-concrete composite structure (CFDST) has been proposed as a novel solution. This structure uses inner and outer double-layered steel tubes to confine the core concrete, and utilizes the concrete to suppress local buckling of the steel tubes, achieving complementary and enhanced material properties and demonstrating excellent mechanical performance and comprehensive economic potential.
[0003] However, transforming CFDST structures from theoretical concepts into reliable products suitable for large-scale engineering applications presents a series of severe technical challenges in manufacturing and construction. Existing technologies, such as composite-concrete-steel double-walled hollow components, while innovative in confining concrete and utilizing material properties, still have significant shortcomings in actual construction processes: First, the lack of a sophisticated deformation control and reinforcement tooling system suitable for steel pipes makes it difficult to guarantee the geometric accuracy of ultra-long components during rolling, assembly, welding, and hoisting. Second, the means to ensure the compactness of the interlayer concrete are limited; detection methods for defects such as voids and air bubbles are singular and inefficient to repair, severely impacting the synergistic performance of steel-concrete. Third, key processes such as prestressing construction and vibration control are often designed separately from the main structure construction, resulting in complex processes, poor coordination, and difficulty in achieving unified optimization of construction efficiency and structural performance. Fourth, the lack of systematic protective measures for highly corrosive marine environments and insufficient durability of anti-corrosion coatings lead to high life-cycle maintenance costs. Summary of the Invention
[0004] In view of the shortcomings of the existing technology, the technical problem to be solved by the present invention is to provide a construction method and tower manufacturing tooling for sandwich steel tube concrete towers. This solves the problems of precision control, concrete compactness assurance and prestressing coordination in the manufacturing of CFDST towers, and significantly improves the structural construction quality, durability and overall economy.
[0005] To achieve the above objectives, the present invention provides a construction method for a sandwiched steel pipe concrete tower, comprising the following steps: S1. Provide an outer cylinder assembly and an inner cylinder assembly, and coaxially arrange the inner cylinder assembly inside the outer cylinder assembly to form an annular cavity; S2. Concrete is poured in sections within the annular cavity to form a sandwiched concrete structure, wherein prestressed duct components are arranged in the annular cavity before at least one pouring stage. S3. Apply tension to the prestressing tendons that pass through the ducts formed by the prestressing duct member; S4. Fill and grout the tensioned duct.
[0006] Furthermore, the steps of providing the outer cylinder assembly and the inner cylinder assembly include: rolling the steel plate into a cylindrical unit and welding the circumferential joint between adjacent cylindrical units to form a cylindrical section; and performing roundness correction after the cylindrical unit is rolled into shape or the cylindrical section is welded.
[0007] Furthermore, during the assembly of the outer cylinder assembly and the inner cylinder assembly to form an annular cavity, a detachable internal support structure is installed inside; before or after the outer cylinder assembly is changed from a horizontal state to a vertical state, the form or structure of the internal support structure is changed.
[0008] Furthermore, the step of pouring concrete in sections within the annular cavity includes: after pouring, testing the compactness of the sandwich concrete structure; and, based on the test results, repairing and grouting the defective areas.
[0009] Furthermore, after the top layer of concrete is poured, a top sealing component is installed, and grouting is performed on the top area of the annular cavity through grouting channels provided on the top sealing component.
[0010] Furthermore, the process of applying tension to the prestressed tendons employs a multi-stage loading method, and the loading sequence follows a symmetrical rule around the tower axis.
[0011] Furthermore, the step of filling the duct with grout includes: injecting grout from the bottom of the duct to allow it to flow upwards and fill the duct; and setting a grout treatment device at the top of the duct to separate or drain excess water from the grout.
[0012] Furthermore, it also includes a step of applying anti-corrosion treatment to the steel structure surface of the tower, wherein the anti-corrosion treatment uses different anti-corrosion processes or materials for at least the outer surface of the tower and the flange contact surface.
[0013] A tooling for use in the tower manufacturing process, comprising: The first type of support assembly is configured to be installed inside the cylinder when the cylinder is in the first orientation and to provide support in the first direction; The second type of support component is configured to replace or supplement the first type of support component when the cylinder is switched to a second position different from the first position, and to provide support adapted to the second position.
[0014] A sandwich steel tube concrete tower is constructed using the aforementioned construction method.
[0015] The beneficial effects of this invention are: The above-mentioned construction method and manufacturing tooling for sandwich steel-concrete composite towers have at least the following advantages: 1. The method constructs a tight and interconnected construction chain from "forming annular cavity - segmented casting (including synchronous pre-embedding) - prestressing tensioning - duct grouting", which changes the previous situation where each process was carried out in isolation and quality control points were scattered. It ensures the quality controllability and coordination of each link from steel frame forming to final structural reinforcement. It is particularly suitable for large tower projects such as offshore wind power with extremely high requirements for precision and reliability.
[0016] 2. This method, through the organic combination of steps S1 and S2, simultaneously completes the pre-embedding of prestressed ducts while constructing a high-precision double-walled steel shell, laying the foundation for the efficient establishment of a high-quality prestressed system in steps S3 and S4. This construction logic of "synchronous growth of the skeleton and meridians" ensures that prestress can be applied evenly and effectively to the formed concrete structure, greatly improving the overall stiffness, crack resistance, and load-bearing capacity of the tower, and fully leveraging the performance advantages of the CFDST composite structure.
[0017] 3. The method described reduces the difficulty and risk of a single construction session through segmented casting (S2), and ensures the long-term durability of the prestressed system through the closed-loop operation of tensioning (S3) and grouting (S4). The integrated process reduces waiting time, rework, and interface treatment issues between processes, thereby improving construction efficiency, shortening the construction period, and reducing the later maintenance costs caused by quality defects, thus optimizing the overall economic efficiency of the structure throughout its entire life cycle. Attached Figure Description
[0018] To more clearly illustrate the specific embodiments of the present invention, the accompanying drawings used in the specific embodiments will be briefly described below. In all the drawings, the elements or parts are not necessarily drawn to scale.
[0019] Figure 1 This invention provides a construction method for a sandwiched steel tube concrete tower, according to an embodiment of the present invention. Figure 2 For the adoption Figure 1 A schematic diagram of a sandwiched steel tube concrete tower constructed using the aforementioned construction method. Figure 3 for Figure 2 A schematic diagram of the top sealing component in a sandwich steel tube concrete tower. Figure 4 for Figure 2 A schematic diagram of the first type of support component in a sandwich steel tube concrete tower. Figure 5 for Figure 2 The diagram shows the first type of support assembly in the sandwich steel tube concrete tower being supported inside the inner cylinder assembly. Figure 6 for Figure 2 A schematic diagram of the second type of support component in a sandwich steel tube concrete tower. Figure 7 for Figure 2 The diagram shows a first type of support component and a first type of support component simultaneously supported inside the inner cylinder component and on the outer cylinder component in a sandwich steel tube concrete tower. Figure 8 for Figure 1 The diagram shows the prestressing tendon threading process in the construction method of sandwich steel tube concrete tower. Figure 9 for Figure 1 The diagram shows the single-stage tensioning sequence in the construction method of sandwich steel tube concrete tower. Figure label: 100-Outer cylinder assembly, 200-Inner cylinder assembly, 300-Prestressed duct component, 400-Prestressed tendon, 500-Top sealing component, 510-Grouting channel, 600-Lower end plate, 700-Class I support component, 800-Class II support component, concrete, flange. Detailed Implementation
[0020] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the invention; therefore, the invention is not limited to the specific embodiments disclosed below.
[0021] Please see Figure 1 This invention provides a construction method for a sandwich steel tube concrete tower, comprising: Step S1: Provide an outer cylinder assembly and an inner cylinder assembly, and coaxially position the inner cylinder assembly inside the outer cylinder assembly to form an annular cavity, thereby constructing a stable double-walled steel shell system as a carrier and template for subsequent construction. The outer and inner cylinder assemblies are typically assembled in a factory or on-site from multiple prefabricated cylinder sections (cylindrical units) through circumferential welding. By coaxially positioning the inner cylinder assembly inside the outer cylinder assembly, temporary supports or positioning fixtures can be used to ensure relative positional accuracy, thus forming an annular cavity of uniform thickness. This cavity not only serves as a space for pouring concrete, but its inner and outer steel cylinders also function as part of the permanent template and load-bearing structure.
[0022] The specific implementation is as follows: First, the outer cylinder assembly and the inner cylinder assembly are prepared separately. The outer cylinder assembly is typically composed of multiple outer cylinder sections, each 3m high (1m for the first and last sections), connected by circumferential welding; the inner cylinder assembly is similarly composed of multiple inner cylinder sections connected together. During assembly, the first inner cylinder section (e.g., 1.5m high) is welded and fixed to the first outer cylinder section (e.g., 1m high) via a lower end plate, thus initially establishing the coaxial relationship between the inner and outer cylinders and forming a stable starting section. Subsequently, all outer cylinder sections are horizontally assembled and welded into a single outer cylinder body (e.g., a total height of 18m), and welded to the bottom flange. Finally, the entire outer cylinder body is hoisted and erected. The remaining parts of the inner cylinder are installed in sections in subsequent steps.
[0023] Step S2: Within the vertical annular cavity, concrete is poured in sections to form a sandwich concrete structure, wherein prestressed duct components are arranged within the annular cavity before at least one pouring stage. Segmented concrete pouring within the formed annular cavity is crucial for controlling construction quality. Segmentation (e.g., 3-5 layers) effectively reduces the amount of concrete poured at a time, lowers the lateral pressure of the concrete on the steel cylinder, and facilitates construction organization and quality control. Pre-embedding prestressed duct components (such as corrugated metal pipes) before at least one pouring stage ensures that the prestressed system is formed synchronously and tightly integrated with the concrete structure. The duct components must be accurately positioned and fixed before pouring to prevent displacement under the impact of concrete.
[0024] Step S3: Apply tension to the prestressing tendons inserted into the ducts formed by the prestressed duct members. After the interlayer concrete reaches its design strength, insert prestressing tendons (such as steel strand bundles) into the pre-embedded ducts and tension them (see...). Figure 8 The purpose of tension prestressing is to actively apply compressive stress to the tower structure to counteract the tensile stress that may be generated during its use (such as wind loads and unit operation), thereby significantly improving the structure's crack resistance, stiffness, and load-bearing capacity.
[0025] For example, after the interlayer concrete reaches its design strength, the prestressed steel strands (e.g., 15.2mm, 1860MPa) are threaded into the pre-embedded corrugated pipe ducts. According to the handover document, the tensioning end is located at the top of the tower, and the fixing end is located at the bottom, using a post-tensioning process. By applying the design tension to the prestressing tendons, compressive stress is actively established in the tower's concrete structure, significantly improving its ability to resist tensile stress generated by operating loads (such as wind loads and turbine vibrations), thereby enhancing the tower's stiffness and crack resistance. Step S4: Fill and grout the tensioned ducts. After tensioning, pressure grouting is performed on the ducts. This step serves three purposes: first, to wrap and protect the prestressing tendons to prevent corrosion; second, to bond the prestressing tendons to the surrounding concrete to achieve effective stress transfer; and third, to fill the ducts to ensure the integrity of the structure.
[0026] The above steps systematically link the precise forming of steel structures, the dense pouring of concrete, the effective establishment of prestress, and the durability protection of structures, avoiding the quality risks caused by the disconnect of processes. This method is particularly suitable for the construction of structures such as offshore wind turbine towers that require high precision.
[0027] In this embodiment, the steps of providing the outer cylinder assembly and the inner cylinder assembly include: rolling a steel plate into a cylindrical unit and welding the circumferential joint between adjacent cylindrical units to form a cylindrical segment; and performing roundness correction after the cylindrical unit is rolled into shape or the cylindrical segment is welded.
[0028] During the rolling of steel plates into cylindrical shapes and the welding of circumferential seams, residual stress and heat input can easily lead to deformations such as ellipticity and localized depressions. Roundness correction aims to eliminate these deformations and restore the cylindrical cross-section to or near its ideal circular shape. In practice, preliminary correction "after the cylindrical unit is rolled into shape" addresses shape deviations in individual sections; correction "after the cylindrical section is welded" primarily addresses the cumulative deformation of the entire section after multiple sections are joined. Correction methods can include returning the cylindrical section to the rolling mill for "rounding" or "returning to roundness," using mechanical force for plastic shaping; or installing adjustable radial support fixtures inside the cylindrical body for correction and fixation through "rounding."
[0029] In practice, roundness correction is carried out in stages: After the cylindrical unit (single section) is rolled: it is rolled into a round shape multiple times by the pressure head on a three-roll plate rolling machine. A 1000mm long inner arc template is used for real-time detection to control the gap between the template and the cylinder wall to ≤2mm, so as to ensure the initial roundness of the single section.
[0030] After longitudinal seam welding of the cylinder section (after multi-section welding): Welding deformation will occur after longitudinal seam welding of the cylinder section. At this time, it is necessary to return it to the plate rolling machine for "rounding" operation to eliminate deformation and ensure that the roundness tolerance of the cylinder section before casting meets the strict standards. (D is the nominal diameter of the outer circle). This is a prerequisite for achieving high-precision assembly.
[0031] After circumferential welding: For long cylindrical sections formed by welding multiple sections together, the overall roundness and straightness also need to be controlled. The target is that the parallelism and coaxiality error of the two end faces of the entire cylindrical section should not exceed 0.3‰ of its height, and the maximum should not exceed 5mm.
[0032] Through the aforementioned phased roundness correction, the geometric accuracy of the steel structure from individual sections to the entire structure was ensured. This directly resulted in three core benefits: first, it ensured the uniform thickness of the annular sandwich cavity, creating conditions for uniform stress on the concrete; second, it made the docking and installation of connecting parts such as flanges more precise and efficient; and third, it ensured that the final stress state of the structure closely matched the design model, improving the structural safety and reliability.
[0033] In this embodiment, during the assembly of the outer cylinder assembly and the inner cylinder assembly to form an annular cavity, a detachable internal support structure is installed inside. Before or after the outer cylinder assembly is changed from a horizontal to a vertical position, the form or structure of the internal support structure is replaced. This solves the problem of easy deformation of the steel cylinder during manufacturing and hoisting.
[0034] The specific implementation method is as follows: When assembling, welding, and storing the cylinder in a horizontal position (first orientation), the main concern is preventing its cross-section from becoming elliptical due to its own weight. In this case, a first-type support assembly, namely a "cross-shaped steel pipe support fixture" (such as...) is installed inside the inner and outer cylinder sections. Figure 4 , 5 8). By adjusting the reverse and forward threads on the tooling, the tightness of the support can be adjusted to actively counteract the deformation tendency.
[0035] When the outer cylinder needs to be moved to a vertical position (second orientation) for hoisting and erection, or when the inner cylinder section needs to be installed in an upright position, the stress shifts to primarily axial pressure and overall bending. In this case, the original horizontal support fixtures may no longer be suitable. Fixture replacement is required before or after the state transition. For example, before erecting the corrosion-resistant outer cylinder, the internal cross-bracing fixtures should be removed, and a specially designed second-type support component, namely the "outer cylinder anti-deformation fixture" (such as...), should be installed. Figure 6 , 7 The design of this fixture is better suited to the stress characteristics of an upright position, providing stable radial constraints and preventing deformation during hoisting and subsequent construction.
[0036] This method achieves precise deformation control that is "adapted to the specific circumstances." By changing appropriate tooling at different stages of the process, it ensures that the steel cylinder maintains its ideal geometric shape throughout the entire process from material cutting and rolling to final installation, effectively suppressing the accumulation of deformation that may be introduced at each stage. This provides a crucial guarantee for achieving the final construction accuracy target (such as roundness tolerance ≤10‰D after pouring).
[0037] In this embodiment, the step of pouring concrete in sections within the annular cavity includes: after pouring, testing the compactness of the sandwich concrete structure; and, based on the test results, repairing and grouting the defective areas. This step aims to establish a closed-loop quality control system of "monitoring-diagnosis-treatment" for internal defects in the sandwich concrete.
[0038] The specific steps are as follows: 1. Inspection: After the concrete is poured, a combination of "manual tapping method" and "impact echo method" is used to conduct full-area void detection. Manual tapping makes a preliminary judgment based on sound, while the impact echo method analyzes the reflection signal of stress waves at the concrete-steel plate interface to more accurately locate the location, area, and even depth of void defects.
[0039] 2. Repair: Based on the inspection results, repair the confirmed defective areas. According to the specific methods outlined in the handover document: First, use carbon arc gouging thermal cutting to precisely drill a hole in the steel plate corresponding to the defect. Then, inject highly fluid, micro-expansion C100 grout into the voided area through this hole, performing pressure grouting until the grout overflows from the vent hole, ensuring the defect is completely filled.
[0040] This solution combines qualitative assessment with quantitative location analysis, forming a complete quality control closed loop of "non-destructive testing discovery - precise hole location - pressure grouting repair". It can detect and eliminate internal defects in the interlayer concrete with near 100% accuracy, ensuring a tight bond between the concrete and the steel pipe wall. This allows the steel and concrete to work together seamlessly, fully leveraging the ultra-high load-bearing capacity and ductility of the CFDST composite structure. In this embodiment: after the top layer of concrete is poured, a top sealing component is installed, and grouting is performed on the top area of the annular cavity through grouting channels provided on the top sealing component. This solves the quality problem of voids easily occurring at the top of the annular cavity due to water seepage and poor air venting.
[0041] Specifically, after the main concrete pouring of the uppermost layer is completed (e.g., poured to 300mm below the reserved upper end plate), the top sealing component, namely the "upper end plate" and stiffening slab, is installed. Multiple grouting channels, such as eight threaded grouting holes, are pre-drilled during the fabrication of this upper end plate, spaced approximately 45° apart along the circumference. Subsequently, supplementary grouting is performed through these grouting holes. The specific operation involves: erecting a temporary platform at the top inside the tower, using two grouting pumps to inject C100 grout into the remaining cavity at the top (approximately 300mm high) through the grouting holes of the upper end plate. A circulating grouting process is adopted, i.e., grouting is performed from one hole, and the grout output from adjacent holes is observed. When all grouting holes are being grouted and adjacent holes are filled with saturated grout, it indicates that the top cavity has been completely filled and compacted, and grouting is stopped.
[0042] This method eliminates the quality risks such as looseness and voids that are difficult to avoid at the top of the structure with traditional casting methods, ensuring the continuity and integrity of the material throughout the entire height of the tower. The upper plate serves three functions: structural enclosure, providing an operating interface, and grouting channel.
[0043] In this embodiment, the step of applying tension to the prestressing tendons adopts a multi-stage loading method, and the loading sequence follows a symmetrical rule around the tower axis (see [link]). Figure 9 Its core principle is to establish effective prestress smoothly, uniformly, and in a controllable manner, so as to avoid structural torsion or excessive local stress.
[0044] Specifically, Multi-stage loading can be carried out using a four-stage tensioning method: 20%σ (pre-tensioning) → 50%σ → 75%σ → 105%σ (holding load for 5 minutes) → unloading to 100%σ. Staged loading allows the prestressing tendons, anchorages, and concrete structure to gradually adjust and adapt, which can effectively reduce the instantaneous loss of prestress and the loss of anchorage retraction, and improve the tensioning control accuracy.
[0045] Symmetry Rule: The tensioning sequence must follow the principle of symmetry around the tower axis. For example, within a tensioning stage (such as 20%σ), first tension a group of four holes spaced 90° apart, then proceed counterclockwise to the next group of adjacent holes. This sequence ensures that the resultant prestress applied to the tower section remains close to the center during tensioning, avoiding additional bending moments or torsion caused by asymmetrical tensioning, and guaranteeing the stability of the tower during construction and the uniformity of the final prestress.
[0046] This method, combining graded and symmetrical tensioning, effectively improves the construction quality and safety of multi-channel prestressed towers. It allows for the smooth and even introduction of massive prestress into the structure, making the tensioning process controllable. The final prestress distribution closely matches the design expectations, significantly enhancing the tower's fatigue resistance and long-term reliability. In this embodiment, the step of filling the duct with grout includes: injecting grout from the bottom of the duct to allow it to flow upwards and fill the duct; and setting a grout treatment device at the top of the duct to separate or drain excess water from the grout.
[0047] In practice, grout is introduced through the grouting hole at the bottom of the duct during grouting. Under the combined action of pumping pressure and its own gravity, the grout fills the entire duct from bottom to top. This method naturally drives the air in the duct upwards and discharges it through the pre-set vent at the top, which is beneficial for forming a continuous, air-filled grout column.
[0048] The top-mounted grout treatment device consists of a funnel-shaped grout draining device installed at the anchor at the top of the duct to address the issue of water seepage in the grout before solidification. Because the water in the grout has a low density, it floats and accumulates in the vertical duct. By injecting slightly more grout than the duct volume, excess water and a small amount of floating grout overflow into the top-mounted draining device, ensuring that the grout remaining in the prestressed duct is a high-quality grout with a suitable water-cement ratio and high density.
[0049] This step effectively solves the problem of weak layers or water pockets forming at the top of vertical ducts due to water seepage, ensuring that the prestressing tendons are protected by dense, high-strength grout along their entire length. This greatly enhances the durability of the prestressing system, preventing corrosion and stress corrosion of the prestressing tendons, which is crucial for offshore wind turbine towers with a design life of decades.
[0050] In a preferred embodiment, the method further includes a step of applying anti-corrosion treatment to the steel structure surface of the tower, wherein the anti-corrosion treatment employs different anti-corrosion processes or materials for at least the outer surface of the tower and the flange contact surface.
[0051] Specifically, it includes: Tower exterior surface: directly exposed to the marine atmosphere (C5-M / C5-VH corrosive environment). A top-grade epoxy graphene zinc primer (60μm) + epoxy intermediate coat (200μm) + polyurethane topcoat (60μm) system is used. The addition of graphene enhances the shielding and cathodic protection of the coating, while the topcoat provides weather resistance.
[0052] Flange contact surface: As a high-strength bolt friction connection, it requires a stable coefficient of friction and corrosion resistance, and should not be too thick as this would affect connection accuracy. Therefore, a different process than the outer surface is used: thermal spraying zinc, with a coating thickness of 160μm±50μm. The metal spray coating provides both corrosion protection and suitable surface roughness.
[0053] Other parts: The inner surface of the tower adopts the C4-VH grade system (primer + intermediate paint); the inner wall of the prestressing tendon duct is sandblasted and then coated with 80μm graphene zinc-rich primer.
[0054] This tiered corrosion protection system ensures ultimate protection for the surface directly exposed to the sea, meets the frictional stress requirements of critical connection points, and also protects the internal structure, significantly reducing the maintenance cost and frequency throughout the entire life cycle. In this invention, a tooling system for providing internal support during the manufacturing process of a tower shell is also provided, the system comprising: The first type of support assembly is configured to be installed inside the cylinder when the cylinder is in the first orientation and to provide support in the first direction; The second type of support component is configured to replace or supplement the first type of support component when the cylinder is switched to a second position different from the first position, and to provide support adapted to the second position.
[0055] Specifically: The first type of support assembly (for horizontal positions): its typical representative is the "cross-shaped steel pipe support fixture" (such as...). Figure 4 , 5 7). It consists of a central hub and multiple radially adjustable screws (or steel pipes with reverse screws), which provide uniform radial support force (support in the first direction) by screwing and adjusting, effectively resisting the elliptical deformation of the cylinder under its own weight. It is suitable for the cylinder in the state of assembly, welding, and horizontal storage (first orientation).
[0056] The second type of support component (for vertical orientation): a typical example is the "outer / inner cylinder anti-deformation fixture" (such as...). Figure 6 and Figure 7 Its construction differs from that of the cross bracing; it is typically a more robust frame structure that may include circumferential reinforcing rings and axial support rods. It is designed to replace the original cross bracing fixtures after the cylinder is converted to a vertical position (second orientation) and to provide support against local instability under lifting forces and vertical loads (adapted to the second orientation support).
[0057] This tooling system instrumentates and standardizes anti-deformation measures, greatly improving the standardization and efficiency of construction and reducing quality risks caused by incompatible tooling. It is a key piece of equipment to ensure the precision of structural manufacturing.
[0058] In addition, the present invention also provides a hollow sandwich steel tube concrete tower, which is manufactured by the above-described construction method.
[0059] The towers constructed using this method possess the advantages of rapid steel structure construction, high rigidity and durability of concrete structures, and excellent crack resistance of prestressed structures. They are particularly suitable for large, tall structures such as megawatt-class offshore wind power towers, communication towers, and transmission towers that have extremely high requirements for load-bearing capacity, fatigue life, and durability.
[0060] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. 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 or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.
Claims
1. A construction method for a sandwiched steel-concrete composite tower, characterized in that, Includes the following steps: S1. Provide an outer cylinder assembly and an inner cylinder assembly, and coaxially arrange the inner cylinder assembly inside the outer cylinder assembly to form an annular cavity; S2. Concrete is poured in sections within the annular cavity to form a sandwiched concrete structure, wherein prestressed duct components are arranged in the annular cavity before at least one pouring stage. S3. Apply tension to the prestressing tendons that pass through the ducts formed by the prestressing duct member; S4. Fill and grout the tensioned duct.
2. The construction method according to claim 1, characterized in that, The steps of providing the outer cylinder assembly and the inner cylinder assembly include: rolling steel plates into cylindrical units and welding the circumferential joints between adjacent cylindrical units to form a cylinder segment; and performing roundness correction after the cylindrical units are rolled into shape or the cylinder segments are welded.
3. The construction method according to claim 1, characterized in that, During the assembly of the outer cylinder assembly and the inner cylinder assembly to form an annular cavity, a detachable internal support structure is installed inside; before or after the outer cylinder assembly is changed from a horizontal to a vertical state, the form or structure of the internal support structure is changed.
4. The construction method according to claim 1, characterized in that, The step of pouring concrete in sections within the annular cavity includes: after pouring, testing the compactness of the sandwich concrete structure; and, based on the test results, repairing and grouting the defective areas.
5. The construction method according to claim 1, characterized in that, After the top layer of concrete is poured, the top sealing component is installed, and the top area of the annular cavity is supplemented with grout through the grouting channel set on the top sealing component.
6. The construction method according to claim 1, characterized in that, The process of applying tension to the prestressed tendons adopts a multi-stage loading method, and the loading sequence follows a symmetrical rule around the tower axis.
7. The construction method according to claim 1, characterized in that, The steps of filling and grouting the duct include: injecting grout from the bottom of the duct to allow it to flow upwards and fill the duct; and setting a grout treatment device at the top of the duct to separate or drain excess water from the grout.
8. The construction method according to claim 1, characterized in that, It also includes a step of anti-corrosion treatment of the steel structure surface of the tower, wherein the anti-corrosion treatment uses different anti-corrosion processes or materials for at least the outer surface of the tower and the flange contact surface.
9. A tooling for use in the tower manufacturing process, characterized in that, include: The first type of support assembly is configured to be installed inside the cylinder when the cylinder is in the first orientation and to provide support in the first direction; The second type of support component is configured to replace or supplement the first type of support component when the cylinder is switched to a second position different from the first position, and to provide support adapted to the second position.
10. A sandwich-type steel-tube concrete tower, characterized in that, It is manufactured by the construction method described in any one of claims 1 to 8.