Slope concrete pouring method and slope concrete pouring formwork system

Abstract

This invention relates to the field of construction engineering technology, providing a method for pouring concrete on a slope and a cover formwork system for pouring concrete on a slope. The method includes: formwork construction: constructing a base formwork at the bottom of the slope and installing a cover formwork on top of the base formwork, so that the cover formwork and the base formwork form an enclosed space for concrete pouring; concrete pouring: pouring concrete into the enclosed space along the slope direction; and vibration compaction: inserting a vibrator into the concrete in the enclosed space through a vibration operation hole opened on the cover formwork for vibration compaction; wherein, the enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope surface. This invention constrains the flow of concrete by forming an enclosed space with the cover formwork and the base formwork, and ensures compaction through a coordinated vibration system, realizing the transformation of slope concrete pouring from uncontrollable to parameter-controlled, ensuring structural quality and construction safety.

Description

Technical Field

[0001] This invention relates to the field of construction technology, and in particular to a method for pouring concrete on a slope and a formwork system for pouring concrete on a slope. Background Technology

[0002] With the continuous advancement of urban construction and underground space development, sloping concrete structures are widely used in projects such as underground parking garages, subway entrances and exits, open tunnel sections, and municipal slope protection to meet the requirements for passage, drainage, structural slope finding, and stress resistance. Sloping concrete generally has characteristics such as large slope, thin cross-section, inclined pouring surface, and easy concrete slippage. Its pouring and compaction control have always been common technical challenges in underground engineering and slope engineering.

[0003] Currently, the mainstream construction method for slope concrete pouring is still traditional, which can be mainly divided into two categories. At the same time, the supporting formwork system has obvious limitations, as follows: 1. Open casting method without mold Side forms are set only on both sides of the slope, and the top surface of the concrete is completely open. The slope and thickness are controlled by manual spreading, vibration and finishing.

[0004] Key issues: Concrete slides down the slope under gravity, resulting in significant segregation of aggregate and mortar, leading to aggregate accumulation at the bottom of the slope and mortar enrichment at the top, resulting in poor structural uniformity; the vibrator is limited by the slope angle, making it difficult to insert to the specified depth, which can easily lead to insufficient vibration, inability to expel internal air bubbles, and difficulty in ensuring compaction; the surface is prone to cracks, honeycombing, pitting, and poor flatness, resulting in a large amount of repair work later.

[0005] 2. Simple Covering Pouring Method Some projects have attempted to cover the concrete top surface with simple formwork (bamboo plywood or scaffolding), which can suppress concrete slippage to some extent, but the following problems exist: Lack of effective constraint mechanisms: Although templates can play a covering role, they cannot be used on a large scale due to limitations in reinforcement, vibration, and material cutting, making it difficult to form an effective enclosed space; Vibration operation is limited: after the cover mold is closed, the vibrator cannot be inserted, or the cover mold needs to be opened frequently, resulting in low construction efficiency and difficulty in ensuring vibration quality. Limited functionality: It does not consider the integration of multiple functions such as exhaust, material feeding, and observation, resulting in poor construction convenience.

[0006] 3. Limitations of traditional template technology Regarding template technology, traditional solutions mainly have the following shortcomings: Low modularity: Traditional templates are mostly cut and assembled on site, resulting in poor dimensional accuracy, difficulty in joint treatment, and difficulty in adapting to flexible adjustments for different slopes and structural dimensions; Functional fragmentation: The functions of formwork fixing, rebar positioning, and vibration operation are all independent, requiring a large number of additional accessories, making construction cumbersome; Low template turnover rate: Bamboo plywood and scaffolding boards and other formwork materials need to be cut in large quantities during use, and the removal process is prone to edge damage, resulting in loose splicing and inability to be reused. Construction of a large number of sloping sections will result in a large waste of materials.

[0007] Lack of digital design tools: Template design relies on on-site experience, resulting in frequent problems such as splice conflicts and steel bar interference, and a high rework rate.

[0008] In summary, traditional sloping concrete pouring technology faces the following pressing technical problems that need to be addressed: 1. Lack of core constraint mechanisms Traditional solutions fail to fundamentally address the gravitational component of concrete on slopes. Traditional unformed construction or simple covering methods cannot create an effective enclosed constraint space, making concrete slippage and segregation unavoidable, directly impacting structural load-bearing capacity and service safety.

[0009] 2. Disconnection between vibration and pouring processes In traditional solutions, the vibration operation and the formwork system lack coordinated design. Functions such as vibration holes, venting holes, and discharge holes are set up separately, or the needs of vibration operation are not considered at all, resulting in the inability to form an effective coordination between "vibration-venting-discharge", and poor controllability of concrete density.

[0010] 3. Low functional integration The functions of formwork fixing, rebar positioning, vibration operation, and air venting observation are all independent, requiring a large number of additional accessories, resulting in low construction efficiency. Furthermore, the lack of coordination between the various functional components makes it difficult to ensure consistent construction quality.

[0011] 4. The contradiction between economy and applicability Traditional formwork materials are limited and do not consider the varying needs of different project turnover rates. High-cost aluminum formwork is used for low-turnover projects, resulting in poor economic efficiency; while low-turnover bamboo plywood is used for high-turnover projects, leading to significant material waste and low levels of green construction.

[0012] 5. Weak quality control throughout the entire process There is a lack of effective coordination between the various stages of template design, processing, installation, pouring, and acceptance. Construction feasibility was not fully considered during the design phase, resulting in frequent on-site problems, high rework rates, and difficulty in building a quality management system that can control the entire process. Summary of the Invention

[0013] The purpose of this invention is to solve at least one technical problem in the background art and to provide a method for pouring concrete on a slope and a cover formwork system for pouring concrete on a slope.

[0014] To achieve the above objectives, the present invention provides a method for pouring concrete on a slope, comprising the following steps: Template construction: A base formwork is built at the bottom of the slope, and a cover formwork is installed above the steel reinforcement skeleton of the slope, so that the cover formwork and the base formwork form an enclosed space for concrete pouring. Concrete pouring: Concrete is poured into the enclosed space along the slope direction; Vibration compaction: Vibration devices are inserted into the concrete within the enclosed space through vibration operation holes opened on the cover mold to compact the concrete. The enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope.

[0015] According to one aspect of the present invention, the cover mold is assembled from a plurality of modular template units, which are fixedly connected by connectors.

[0016] According to one aspect of the present invention, the vibration operation hole includes a vibration hole and a vibration groove, both of which are formed on the cover mold; The vibratory grooves are arranged longitudinally along the slope on the cover mold, serving as material discharge holes and auxiliary vibration channels; the vibratory holes and vibratory grooves together constitute a synergistic vibration system.

[0017] According to one aspect of the invention, the vibratory holes are arranged in a rectangular array on the cover mold with a row spacing of 80 cm and a column spacing of 80 cm; the vibratory grooves are provided every 3-5 meters, with a width of 30-50 cm.

[0018] According to one aspect of the present invention, the template construction further includes: setting short side wall templates at the longitudinal two sides of the cover mold, the short side wall templates being used to form the lateral boundaries of the concrete pouring; The bottom plane of the short side wall formwork is provided with a serrated groove. The spacing of the serrated groove matches the spacing of the reinforcing bars in the structure to be poured. This is used to insert the reinforcing bars into the serrated groove, thereby simultaneously restricting the planar position of the reinforcing bars and fixing the short side wall formwork to the reinforcing bars, thus realizing the integration of formwork fixing and reinforcing bar limiting.

[0019] According to one aspect of the present invention, in the template construction step, the material is selected differently according to the required number of template turnovers: bamboo plywood is used when the template is used 1-2 times, plastic template is used when the template is used 3-10 times, and aluminum template is used when the template is used more than 10 times.

[0020] According to one aspect of the present invention, in the formwork erection step, a BIM model is used to design the formwork unit size, vibration hole position and joint position of the cover formwork, so that the vibration hole avoids the position of the reinforcing steel in the structure to be poured, and eliminates the interference between the joints between the formwork units and the reinforcing steel. A test section with the same slope as the slope was built on the ground. Bamboo plywood and square timber were used for template assembly, reinforcement and simulated vibration to verify the rigidity, stability and feasibility of vibration operation of the template system, and to retain construction parameters.

[0021] According to one aspect of the present invention, the cover mold is fixed by a support system, the support system comprising: an aluminum square tube back rib disposed on the back of the cover mold, the spacing between adjacent back ribs being 30cm; a double-ply φ48×3.5mm steel pipe disposed every 90cm along a direction perpendicular to the back rib; tie rods arranged in a 90cm×90cm grid pattern, the tie rods being welded to pre-embedded reinforcing bars, the pre-embedded reinforcing bars being welded to the bottom plate reinforcing bar skeleton; and thickened aluminum blocks being welded to the edges of the vibrating holes.

[0022] According to one aspect of the present invention, in the concrete pouring step, the concrete is poured in sections from bottom to top along the slope, each section being 3-5m long, and the interval between the sections is less than or equal to the initial setting time of the concrete; after the concrete is poured, it is covered with geotextile and watered for curing before the initial setting time, and the curing time is greater than or equal to 14 days.

[0023] According to one aspect of the invention, in the vibration compaction step, the vibration device is inserted to a depth of 50 mm below the surface of the lower concrete layer, and the vibration time is 20-30 seconds, until the concrete surface no longer sinks, no air bubbles emerge, and a uniform slurry appears.

[0024] According to one aspect of the invention, the method further includes curing and formwork removal: the cover formwork is removed when the concrete strength reaches 50% of the design strength, part of the support system is removed when it reaches 75%, and the entire support system is removed when it reaches 100%; the removal sequence is carried out in sections from top to bottom, and the length of each section is ≤3m.

[0025] To achieve the above objectives, the present invention also provides a cover formwork system for pouring concrete on slopes, comprising: The base formwork is laid at the bottom of the slope; A cover mold is set above the base template, forming an enclosed space with the base template for concrete pouring; A vibration operation hole is provided on the cover mold for inserting the vibration device and venting air. The enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope.

[0026] According to the present invention, the formwork and the base formwork create a closed or semi-closed enclosed space, restricting the free flow of concrete on the slope and fundamentally suppressing the downward trend of concrete and the separation of aggregate and slurry. The enclosed space allows the concrete to maintain a stable spatial shape before solidification, avoiding the quality defects of accumulation at the bottom of the slope and rich slurry at the top of the slope in traditional open pouring.

[0027] This invention provides a stable channel for the vibration device to reach the interior of the concrete through vibration operation holes (including vibration holes and vibration grooves) opened on the cover mold, overcoming the spatial limitations of vibration operation on slopes. The vibration holes are distributed in an 80cm×80cm rectangular array, and the vibration grooves are set at intervals of 3-5 meters, forming a synergistic vibration system of holes and grooves. This achieves a combination of precise point vibration and continuous linear vibration, ensuring effective energy transfer and full expulsion of air bubbles. It solves the inherent defects of traditional slope vibration, such as insufficient penetration and incomplete compaction, ensuring that the concrete is both internally solid and externally aesthetically pleasing.

[0028] The formwork of this invention adopts a modular template unit assembly design, which can flexibly adjust the combination method according to the slope, length and structural dimensions of different projects, and is suitable for a conventional slope range of 5° to 30°. The modular design makes individual units easy to transport, hoist and quickly assemble on site, and the fixed connection method of the connectors simplifies the construction process and improves the adaptability of the formwork system to complex slope structures.

[0029] The serrated groove on the short side wall template of the present invention realizes the integration of template fixing and rebar limiting. After the rebar is inserted into the serrated groove, the planar position is determined and the template is fixed at the same time, reducing the use of independent accessories. The vibration hole also serves as an air vent and observation hole, and the vibration groove also serves as a material discharge hole, realizing multiple functions in one, simplifying the construction process, and reducing material costs and labor input.

[0030] This invention selects materials based on the different turnover times of the template (bamboo plywood for 1-2 times, plastic templates for 3-10 times, and aluminum templates for more than 10 times), so that the cost of the template matches the actual needs of the project, avoids the waste of high-value materials with low turnover or the high cost of low-turnover materials, reduces material waste, and meets the requirements of green construction.

[0031] This invention uses a BIM model to digitally design the dimensions of formwork units, the location of vibration holes, and the location of joints, thus avoiding interference with reinforcing bars and conflicts at joints in advance. Ground test sections are used to verify the stiffness, stability, and feasibility of vibration operation of the formwork system, preserving construction parameters. The combination of virtual design and physical verification constructs a closed-loop technology system encompassing design, testing, installation, pouring, and acceptance, transforming experience-based operations into parametric control and reducing rework rates.

[0032] The support system of this invention employs aluminum square tube back braces (30cm spacing), double-layered steel pipes (90cm spacing), and 90cm×90cm grid-like tie rods to form a three-level force transmission system of surface, line, and point, ensuring the stability of the formwork under the lateral pressure of concrete and the impact force of vibration. Thickened aluminum blocks are welded to the edges of the vibration holes to reinforce key areas. A tiered formwork removal strategy (removing the formwork at 50% strength, partially removing supports at 75%, and completely removing all supports) combined with top-down segmented dismantling achieves gradual load transfer, ensuring a safe structural transition and finished product quality.

[0033] This invention employs segmented pouring control (from bottom to top, each segment 3-5m long, with intervals not exceeding the initial setting time) to avoid cold joints between layers; vibration parameter control (insertion 50mm into the lower layer, time 20-30s, stopping at surface condition) to ensure dense interlayer bonding; and curing control (covering before initial setting, for at least 14 days) to ensure full hydration of the concrete. The entire process is parameterized and controlled to ensure the load-bearing capacity, durability, and safety of the sloping concrete structure. Attached Figure Description

[0034] Figure 1 The flowchart schematically illustrates a method for pouring concrete on a slope according to one embodiment of the present invention. Detailed Implementation

[0035] The invention will now be discussed with reference to exemplary embodiments. It should be understood that the described embodiments are merely intended to enable those skilled in the art to better understand and thus implement the invention, and are not intended to imply any limitation on the scope of the invention.

[0036] As used herein, the term "comprising" and its variations are to be interpreted as open-ended terms meaning "including but not limited to". The term "based on" is to be interpreted as "at least partially based on". The terms "one embodiment" and "an embodiment" are to be interpreted as "at least one embodiment".

[0037] Figure 1 A flowchart illustrating a method for pouring concrete on a slope according to an embodiment of the present invention is shown. Figure 1 As shown, in this embodiment, the method for pouring concrete on a slope includes the following steps: Formwork erection: The base formwork is erected at the bottom of the slope (middle slab, top slab), and the cover formwork is installed above the steel reinforcement skeleton of the slope, so that the cover formwork and the base formwork form an enclosed space for concrete pouring. Concrete pouring: Pour concrete into the enclosed space along the slope direction; Vibration compaction: Vibration devices are inserted into the concrete within the enclosed space through vibration operation holes opened on the cover mold to compact the concrete. The enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope.

[0038] In this embodiment, during the pouring of concrete on a slope, gravity causes the concrete to slide down the slope, resulting in aggregate separation from the grout, accumulation at the bottom of the slope, and grout enrichment at the top, severely affecting the structural uniformity and load-bearing capacity. This invention uses a cover formwork and a base formwork to create a closed or semi-closed enclosed space, restricting the flow freedom of the concrete in three dimensions. This enclosed space, through the vertical constraints of the cover formwork and base formwork, limits the displacement of the concrete in the direction perpendicular to the slope, thereby suppressing segregation and stratification under gravity. Simultaneously, the cover formwork provides a top boundary for the concrete, and combined with the friction between the concrete and the base formwork, as well as lateral constraints (such as end formwork or reinforcing steel reinforcement), effectively resists the tendency of the concrete to slide down the slope. Compared to traditional open pouring methods that rely solely on side formwork constraints or manual finishing, the enclosed space maintains a stable spatial shape for the concrete before solidification, ensuring that the slope of the solidified structure matches the design and avoiding dimensional deviations and uneven strength caused by sliding.

[0039] In traditional sloping concrete pouring, vibrators are difficult to insert to the specified depth, resulting in inherent defects such as insufficient insertion and inadequate compaction. Air bubbles within the concrete cannot be fully expelled, making it difficult to guarantee density. This invention provides a stable channel for the vibrator to reach the interior of the concrete by creating a vibration operation hole in the formwork. The formwork itself constitutes a rigid operating platform, allowing the vibrator to overcome the angle limitations of the slope and be inserted vertically or at an angle to the specified depth as required by specifications. Simultaneously, the enclosed space provides a stable working environment for vibration, effectively transferring vibration energy to the interior of the concrete, promoting the full expulsion of air bubbles, and significantly improving concrete density. This design organically combines the formwork constraint function with the vibration operation function, transforming sloping concrete pouring from an uncontrollable flow state to a controllable compaction state, achieving the quality goal of internal solidity and external aesthetics in sloping concrete.

[0040] Furthermore, according to one embodiment of the present invention, the cover mold is assembled from multiple modular template units, which are fixedly connected by connectors.

[0041] In this embodiment, structural dimensions, slope angles, and planar shapes often vary in sloping concrete pouring projects, making traditional monolithic formwork difficult to adapt to changing construction site conditions. This invention decomposes the cover formwork into multiple modular formwork units. The number and combination of these units can be flexibly adjusted according to the slope length, width, and slope parameters of the specific project, enabling rapid construction of enclosed spaces of different specifications. The formwork units are fixedly connected via connectors, ensuring the stability of the overall structure after assembly while allowing for local adjustments based on on-site measurement data. This effectively solves the problems of poor adaptability and cumbersome on-site cutting and modification caused by traditional one-size-fits-all formwork, significantly improving the formwork system's adaptability to complex sloping structures.

[0042] Modular design keeps the size and weight of individual formwork units within a range that facilitates manual handling and mechanical hoisting, reducing the difficulty and labor intensity of on-site installation. Compared to large monolithic formwork, modular units enable standardized prefabrication, batch processing, and rapid on-site assembly, significantly shortening the formwork construction period. Simultaneously, the fixed connection method of the connectors simplifies the assembly process, requiring no complex professional skills and improving construction efficiency. After project completion, modular units can be easily disassembled, categorized, and stacked for easy transfer to the next construction section or reuse within the project, increasing the turnover rate of the formwork system and reducing per-use amortization costs.

[0043] The connectors between the formwork units not only achieve mechanical fixation, but also ensure the flatness and sealing of adjacent units after splicing through standardized interface design, reducing the risk of grout leakage at the joints. The continuous cover surface formed by the connection maintains the structural integrity of the enclosed space, ensuring a uniform distribution of the function of restraining concrete flow and avoiding deformation or grout leakage caused by weak local connections, thereby guaranteeing the consistency of surface quality and structural performance of the concrete after molding.

[0044] Furthermore, according to one embodiment of the present invention, the vibration operation hole includes a vibration hole and a vibration groove, both of which are formed on the cover mold; The vibratory troughs are set longitudinally along the slope on the cover mold, serving as material discharge holes and auxiliary vibration channels; the vibratory holes and vibratory troughs together constitute a coordinated vibration system.

[0045] In this embodiment, vibration holes are formed on the cover formwork, creating a matrix-distributed array of conventional vibration points to meet the standard spacing requirements for vibrator insertion. These holes are primarily used for the routine removal and compaction of air bubbles within the concrete. Vibration grooves are spaced longitudinally along the slope, with a width significantly larger than the vibration holes, serving as both discharge ports and auxiliary vibration channels. Together, they form a clearly defined operational system: the vibration grooves act as the main entry point for concrete injection into the enclosed space, solving the problem of difficult concrete transport during slope pouring, and also serve as auxiliary channels for deep vibration, addressing areas difficult to cover by the vibration holes; the vibration holes focus on precise vibration and venting. This functional integration avoids the weakening of the cover formwork structure and the risk of grout leakage caused by the separate opening of discharge ports, vibration ports, and vents required in traditional construction, achieving a highly efficient operational mode of multi-purpose holes and coordinated hole-groove operation.

[0046] In sloping concrete pouring, gravity causes concrete to flow along the slope, making it difficult to uniformly control the density at different elevations. The matrix distribution of vibratory holes ensures that any location within the enclosed space is within the standard vibration radius, achieving uniform surface vibration. The longitudinal spacing of the vibratory troughs addresses the flow characteristics of concrete along the slope, providing enhanced vibration and material replenishment channels at key elevation nodes. The spatial layout of these two elements works in tandem: the vibratory holes provide precise point vibration, while the vibratory troughs provide continuous linear vibration and material replenishment, together forming a three-dimensional vibration network covering the entire slope cross-section. This collaborative system overcomes the shortcomings of traditional sloping concrete vibration methods, such as insufficient depth and incomplete compaction, ensuring that vibration energy is effectively transferred to all layers of the concrete, allowing air bubbles to escape fully, and significantly improving the overall density and uniformity of the sloping concrete.

[0047] The design of the vibratory trough, which also serves as a discharge port, allows for simultaneous and coordinated concrete pouring and vibration operations. After concrete is injected into the trough, it can be immediately vibrated in adjacent discharge ports, achieving a seamless connection between the discharge and vibration processes. The matrix distribution of the discharge ports allows for simultaneous vibration at multiple points, while the spacing of the vibratory troughs controls the appropriate length of segmented pouring. Together, these factors ensure that the concrete is compacted before initial setting, avoiding cold joint problems caused by excessively long pouring intervals. Simultaneously, the wide opening of the vibratory trough allows for flexible adjustment of the vibrator's insertion angle and depth, adapting to the vibration requirements of different slope elevations. This improves the operability and construction efficiency of the vibration operation, ensuring the achievement of the quality goal of internal compaction and external aesthetics in the slope concrete.

[0048] Furthermore, according to one embodiment of the present invention, the vibration holes are distributed in a rectangular array on the cover mold with a row spacing of 80cm and a column spacing of 80cm; the vibration groove is set every 3-5 meters, with a width of 30-50cm.

[0049] In this embodiment, the vibratory holes are distributed in an 80cm×80cm rectangular array. This spacing matches the effective radius of a conventional vibrator, ensuring that the effective ranges of adjacent vibratory holes are interconnected without significant overlap, achieving uniform coverage of vibration energy within the enclosed space. This parameter design allows air bubbles inside the concrete to migrate and be expelled along the shortest path to the nearest vibratory hole during vibration, reducing blind spots and improving air release efficiency. Vibratory troughs are installed every 3-5 meters, with a width of 30-50cm. This interval is adapted to the segmented pouring length, providing ample channels for concrete delivery and forming reasonable vibration operation units between adjacent troughs. This allows the point-like effect of the vibratory holes and the linear effect of the vibratory troughs to complement each other spatially, jointly ensuring the longitudinal density continuity of the slope.

[0050] The above parameter combination satisfies the requirements of vibration and material feeding functions, while avoiding the weakening of the cover form structure caused by excessively dense openings, maintaining the cover form's ability to constrain the concrete, and facilitating on-site construction operations and quality control.

[0051] Furthermore, according to one embodiment of the present invention, the template construction further includes: setting short side wall templates on both longitudinal sides of the cover mold, the short side wall templates being used to form the lateral boundaries of the concrete pouring; The bottom plane of the low side wall formwork has a serrated groove. The spacing of the serrated groove matches the spacing of the reinforcing bars in the structure to be poured. This is used to insert the reinforcing bars into the serrated groove, thereby simultaneously restricting the planar position of the reinforcing bars and fixing the low side wall formwork to the reinforcing bars, thus achieving the integration of formwork fixing and reinforcing bar limiting.

[0052] In this embodiment, based on the enclosure formed by the cover formwork and the base formwork, short side wall formwork is set on both longitudinal sides to further improve the three-dimensional boundary conditions of the enclosed space. The short side wall formwork, together with the cover formwork and the base formwork, constitutes a closed or semi-closed three-dimensional casting space, applying lateral restraint forces to the concrete from both longitudinal sides to prevent the concrete from flowing and overflowing along the slope. This design upgrades the enclosure space from surface constraint to volume constraint, comprehensively restricting the degrees of freedom of the concrete, ensuring that the concrete maintains its design contour during the solidification process, and avoiding cross-sectional dimension deviations and edge quality defects caused by lateral expansion or loss.

[0053] The serrated grooves on the bottom plane of the low side wall formwork are precisely matched with the spacing of the reinforcing bars, allowing the bars to be directly inserted into the grooves. This design combines the two traditional construction processes of first setting up the formwork and then threading the reinforcing bars, or first laying the reinforcing bars and then setting up the formwork, into one: after the reinforcing bars are inserted into the serrated grooves, their accurate position in the plane is determined, preventing them from shifting or floating, and the rigidity of the reinforcing bars is used to fix the low side wall formwork in the designed position, achieving the interaction of fixing the formwork with reinforcing bars and limiting the reinforcing bars with the formwork. This integrated functional design reduces the number of independent accessories (such as reinforcing bar clamps, formwork supports, etc.) used for fixing the formwork and limiting the reinforcing bars in traditional construction, simplifying the number of components and installation procedures, and reducing material costs and labor input.

[0054] The precise matching of the serrated grooves with the reinforcing bars ensures a uniform and consistent thickness of the concrete cover, preventing insufficient or excessive cover due to rebar misalignment and guaranteeing the structure's durability and load-bearing capacity. Simultaneously, the formwork, fixed by the reinforcing bars, exhibits enhanced positional stability, making it less prone to displacement or deformation during concrete pouring and vibration, thus improving the reliability of construction quality. This design interconnects and cross-checks the construction precision of the reinforcing bar and formwork engineering, forming natural quality control nodes during construction and reducing systemic deviations caused by the accumulation of errors in individual construction items.

[0055] Furthermore, according to one embodiment of the present invention, in the template erection step, the material of the cover template is selected differently according to the required number of template turnovers: bamboo plywood is used when the template is used 1-2 times, plastic template is used when the template is used 3-10 times, and aluminum template is used when the template is used more than 10 times.

[0056] In this implementation, materials are selected based on the different turnover rates to match the formwork cost with the actual needs of the project. Low-turnover projects use lower-cost bamboo plywood to avoid wasting high-value materials; high-turnover projects use durable aluminum formwork, reducing the cost per use through multiple amortizations and optimizing economic benefits.

[0057] Different materials exhibit varying properties in terms of rigidity, moisture resistance, and high-temperature resistance. Appropriate selection based on the number of reuses ensures stable structural performance of the formwork during construction, guaranteeing the quality of concrete molding. Simultaneously, it reduces unnecessary material waste and aligns with green construction requirements.

[0058] Furthermore, according to one embodiment of the present invention, in the formwork erection step, a BIM model is used to design the formwork unit size, vibration hole position and joint position of the cover formwork, so that the vibration hole avoids the position of the reinforcing steel in the structure to be poured, and eliminates the interference between the joints between the formwork units and the reinforcing steel. A test section with the same slope as the slope was built on the ground. Bamboo plywood and square timber were used for template assembly, reinforcement and simulated vibration to verify the rigidity, stability and feasibility of vibration operation of the template system, and to retain construction parameters.

[0059] In this implementation, a BIM model is used to digitally design the dimensions of formwork units, the location of vibratory tamping holes, and the location of joints, enabling precise simulation of the spatial relationship between the formwork and reinforcing steel in a virtual environment. Through 3D visualization, conflicts between the location of vibratory tamping holes and reinforcing steel, as well as interference between formwork joints and reinforcing steel, can be identified in advance, allowing for optimization and adjustments during the design phase. This avoids errors and omissions that are difficult to detect in traditional 2D design. This pre-design process transforms formwork design from experience-based estimation to precise calculation, ensuring reasonable vibratory tamping hole locations and that joints avoid reinforcing steel, providing a reliable technical foundation for smooth on-site construction and reducing on-site downtime and rectification due to design flaws.

[0060] A physical test section with the same slope as the ground is constructed. Bamboo plywood and square timber are used for formwork assembly, reinforcement, and simulated vibration. This allows for verification of whether the rigidity and stability of the formwork system meet the lateral pressure requirements of the concrete in a zero-risk environment, and tests the spatial accessibility and convenience of vibration operations. Through the operation of the test section, key parameters such as formwork deformation, stress state of the support system, and vibrator insertion angle can be measured. This allows for the evaluation of the rationality of the formwork design and the feasibility of the construction process, enabling timely identification and resolution of potential problems and avoiding quality accidents or rework losses due to flawed solutions in the actual project.

[0061] Construction parameters retained during the test section verification process, including formwork reinforcement spacing, tie rod preload, vibrator insertion depth and time, etc., form quantifiable and replicable technical standards. These parameters provide clear operational guidelines for subsequent formal construction, transforming the construction process from experience-based operation to parameter-based control, improving the consistency and stability of construction quality. Simultaneously, the cross-verification of BIM design data and measured data from the test section constructs a technical closed loop of virtual design, physical verification, and parameter solidification. This lays the foundation for establishing a comprehensive quality control system covering design, testing, installation, pouring, and acceptance, significantly reducing rework rates and improving the overall quality level of the project.

[0062] Furthermore, according to one embodiment of the present invention, the cover mold is fixed by a three-stage force transmission support system, which consists of a back rib, a transverse steel pipe, and a tie rod, and provides local reinforcement to the vibratory holes, as specifically constructed as follows: (1) An aluminum square tube back rib is provided on the back of the cover mold, and the distance between adjacent back ribs is 30cm; (2) Along the direction perpendicular to the back rib, a double-ply φ48×3.5mm transverse steel pipe is installed every 90cm; (3) Tie rods with a grid arrangement of 90cm×90cm are used. The tie rods are welded to the pre-embedded steel bars, and the pre-embedded steel bars are welded to the bottom plate steel bar skeleton. (4) Weld thickened aluminum blocks to the edge of the vibratory hole for local reinforcement.

[0063] 1. Composition and stress logic of the support system (three-level force transmission: surface-line-point) This support system transmits force step by step through surface support → line distribution → point anchoring, forming a stable force path: Surface support: Aluminum square tube back ribs are continuously arranged longitudinally along the slope to directly bear the lateral pressure of concrete and the impact force of vibration, suppressing local bulging and deformation of the cover formwork and ensuring the rigidity and integrity of the cover formwork surface.

[0064] Line distribution: The double-layered horizontal steel pipes are perpendicular and orthogonal to the back rib to form a grid, which distributes the surface load borne by the back rib laterally, improves the overall flatness of the cover mold, and prevents warping caused by uneven stress.

[0065] Point anchoring: The grid-like tie rods are evenly arranged in a 90cm×90cm grid as the final stress anchoring points, which transfer all the upward thrust and lateral pressure of the cover formwork system to the pre-embedded steel bars, and then into the bottom plate steel reinforcement skeleton and the main structure.

[0066] 2. Anchoring Structure and Mechanical Advantages The tie rods, embedded reinforcing bars, and bottom slab reinforcing bar cage are connected by welding to form a continuous and reliable mechanical transfer path. Relying on the self-weight and rigidity of the main structure, it resists the floating and lateral displacement caused by concrete pouring; The 90cm×90cm grid arrangement ensures even load distribution and avoids stress concentration that could cause localized damage or excessive deformation. No additional ground anchors or external support frames are required, simplifying the support structure, reducing interference with the base formwork and reinforcing steel, and improving the cleanliness and ease of operation of the construction space.

[0067] 3. Local reinforcement of vibratory tamping holes The vibratory hole is a weak point in the opening of the formwork. Welding thickened aluminum blocks to the edge of the hole can significantly improve the deformation resistance and wear resistance of the opening, avoid damage to the hole and leakage of grout caused by repeated insertion and removal of the vibratory rod, and extend the service life of the formwork.

[0068] As the opening of the formwork, the vibratory hole weakens the local rigidity, making it prone to deformation or damage under repeated insertion of the vibrator and concrete pressure. Welding thickened aluminum blocks to the edge of the vibratory hole forms a local reinforcing ring, improving the hole's resistance to deformation and wear, and extending the formwork's service life. This reinforcement measure addresses the frequent use required for vibration operations, ensuring that the vibratory hole maintains its design dimensions and positional accuracy after multiple uses, preserving the smoothness and sealing of the vibrator insertion, preventing grout leakage or vibration difficulties caused by hole edge deformation, and ensuring the stability of construction quality.

[0069] Furthermore, according to one embodiment of the present invention, in the concrete pouring step, the concrete is poured in sections from bottom to top along the slope, with each section being 3-5m long, and the interval between the sections is less than or equal to the initial setting time of the concrete; after the concrete is poured, it is covered with geotextile and watered for curing before the initial setting time, and the curing time is greater than or equal to 14 days.

[0070] In this embodiment, the concrete is poured in sections from bottom to top along the slope, with each section being 3-5m long. The initial setting characteristics of the lower layer of concrete can be used to form a natural water-retaining barrier, reducing the flow distance of the concrete along the slope. Combined with the control that the interval between the sections does not exceed the initial setting time, cold joints between layers are avoided, ensuring the integrity of the structure.

[0071] Before initial setting, cover the concrete with geotextile and spray water for curing to keep the concrete surface moist and prevent surface cracking caused by excessive evaporation of moisture; the curing time should not be less than 14 days to ensure that the concrete is fully hydrated and reaches the design strength.

[0072] Furthermore, according to one embodiment of the present invention, in the compaction step, the vibrating device is inserted to a depth of 50mm below the surface of the lower concrete layer, and the vibration time is 20-30s, until the concrete surface no longer sinks, no air bubbles emerge, and a uniform slurry appears.

[0073] In this embodiment, the vibrating device is inserted to a depth of 50mm below the surface of the lower concrete layer, so that the upper and lower concrete layers are fully fused at the interface, eliminating the weak area at the interlayer bonding surface, forming an integral continuous concrete structure, and improving the shear resistance and bearing capacity of the slope section.

[0074] Controlling the vibration time to 20-30 seconds, along with stopping when the surface no longer sinks, no more bubbles emerge, and a uniform surface slurry appears, ensures that the vibration energy is fully transferred to the interior of the concrete, so that the aggregate is evenly distributed, the bubbles are fully expelled, and the quality requirements for dense concrete are met, avoiding defects such as honeycomb and pitted surfaces.

[0075] Furthermore, according to one embodiment of the present invention, the method further includes curing and formwork removal: the cover formwork is removed when the concrete strength reaches 50% of the design strength, part of the support system is removed when it reaches 75%, and the entire support system is removed when it reaches 100%; the removal sequence is carried out in sections from top to bottom, and the length of each section is ≤3m.

[0076] In this implementation, the development of concrete strength is sequential, and the tiered control of formwork removal timing allows the structure to gradually bear its own load. When 50% of the design strength is reached, the formwork is removed; at this point, the concrete has acquired preliminary load-bearing capacity and can withstand its own weight and construction loads, and the formwork's restraining function has fulfilled its purpose. When 75% is reached, part of the support system is removed to gradually release the support reaction force and test the structure's load-bearing performance during the transition phase. When 100% is reached, all supports are removed, completing the full load transfer. This tiered strategy avoids sudden stress changes caused by one-time removal, prevents early concrete damage or cracking, and ensures the continuity and safety of the structure's strength development.

[0077] Staged formwork removal allows for the phased release of formwork and support systems. Formwork that can be removed at 50% strength can be quickly reused for the next construction section, improving formwork utilization. Delayed removal of some support systems provides continuous curing conditions for the concrete, while reducing the labor and equipment investment required for one-time removal. Segmented removal from top to bottom, with each segment not exceeding 3 meters, ensures that the removal work surface matches the concrete's strength development stage, avoiding disturbance to the lower, under-strength concrete due to removal vibrations, and achieving a reasonable connection between construction procedures.

[0078] The top-down, segmented demolition approach aligns with the structural stress characteristics of the slope, avoiding the safety risks of the upper section being left unsupported due to premature demolition of the lower section. Limiting the length of each demolition segment controls the scope of a single operation, facilitating timely cleanup of demolition materials and preventing concentrated loads from overloading the slope's top slab. This demolition strategy organically combines structural strength development, construction safety control, and finished product protection, ensuring the integrity and stability of the slope's concrete structure during demolding and support transitions.

[0079] Furthermore, to achieve the above objectives, the present invention also provides a cover formwork system for pouring concrete on slopes, comprising: The base formwork is laid at the bottom of the slope; A cover mold is set above the base template, forming an enclosed space with the base template for concrete pouring; A vibration operation hole is provided on the cover mold for inserting the vibration device and venting air. The enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope.

[0080] The above-described cover formwork system for pouring sloping concrete according to the present invention is used to implement the above-described method for pouring sloping concrete. The specific process steps and configuration are as described above and will not be repeated here.

[0081] According to the above-described scheme of the present invention, the present invention restricts the free flow of concrete on the slope by forming a closed or semi-closed enclosed space with the cover mold and the base template, thereby fundamentally suppressing the downward trend of concrete and the separation of aggregate and slurry. The enclosed space allows the concrete to maintain a stable spatial shape before solidification, avoiding the quality defects of accumulation at the bottom of the slope and rich slurry at the top of the slope in traditional open pouring.

[0082] This invention provides a stable channel for the vibration device to reach the interior of the concrete through vibration operation holes (including vibration holes and vibration grooves) opened on the cover mold, overcoming the spatial limitations of vibration operation on slopes. The vibration holes are distributed in an 80cm×80cm rectangular array, and the vibration grooves are set at intervals of 3-5 meters, forming a synergistic vibration system of holes and grooves. This achieves a combination of precise point vibration and continuous linear vibration, ensuring effective energy transfer and full expulsion of air bubbles. It solves the inherent defects of traditional slope vibration, such as insufficient penetration and incomplete compaction, ensuring that the concrete is both internally solid and externally aesthetically pleasing.

[0083] The formwork of this invention adopts a modular template unit assembly design, which can flexibly adjust the combination method according to the slope, length and structural dimensions of different projects, and is suitable for a conventional slope range of 5° to 30°. The modular design makes individual units easy to transport, hoist and quickly assemble on site, and the fixed connection method of the connectors simplifies the construction process and improves the adaptability of the formwork system to complex slope structures.

[0084] The serrated groove on the short side wall template of the present invention realizes the integration of template fixing and rebar limiting. After the rebar is inserted into the serrated groove, the planar position is determined and the template is fixed at the same time, reducing the use of independent accessories. The vibration hole also serves as an air vent and observation hole, and the vibration groove also serves as a material discharge hole, realizing multiple functions in one, simplifying the construction process, and reducing material costs and labor input.

[0085] This invention selects materials based on the different turnover times of the template (bamboo plywood for 1-2 times, plastic templates for 3-10 times, and aluminum templates for more than 10 times), so that the cost of the template matches the actual needs of the project, avoids the waste of high-value materials with low turnover or the high cost of low-turnover materials, reduces material waste, and meets the requirements of green construction.

[0086] This invention uses a BIM model to digitally design the dimensions of formwork units, the location of vibration holes, and the location of joints, thus avoiding interference with reinforcing bars and conflicts at joints in advance. Ground test sections are used to verify the stiffness, stability, and feasibility of vibration operation of the formwork system, preserving construction parameters. The combination of virtual design and physical verification constructs a closed-loop technology system encompassing design, testing, installation, pouring, and acceptance, transforming experience-based operations into parametric control and reducing rework rates.

[0087] The support system of this invention employs aluminum square tube back braces (30cm spacing), double-layered steel pipes (90cm spacing), and 90cm×90cm grid-like tie rods to form a three-level force transmission system of surface, line, and point, ensuring the stability of the formwork under the lateral pressure of concrete and the impact force of vibration. Thickened aluminum blocks are welded to the edges of the vibration holes to reinforce key areas. A tiered formwork removal strategy (removing the formwork at 50% strength, partially removing supports at 75%, and completely removing all supports) combined with top-down segmented dismantling achieves gradual load transfer, ensuring a safe structural transition and finished product quality.

[0088] This invention employs segmented pouring control (from bottom to top, each segment 3-5m long, with intervals not exceeding the initial setting time) to avoid cold joints between layers; vibration parameter control (insertion 50mm into the lower layer, time 20-30s, stopping at surface condition) to ensure dense interlayer bonding; and curing control (covering before initial setting, for at least 14 days) to ensure full hydration of the concrete. The entire process is parameterized and controlled to ensure the load-bearing capacity, durability, and safety of the sloping concrete structure.

[0089] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above-described features with (but not limited to) technical features with similar functions disclosed in this application.

[0090] It should be understood that the sequence number of each step in the invention and its embodiments does not absolutely imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

Claims

1. A method for pouring concrete on a slope, characterized in that, Includes the following steps: Template construction: A base formwork is built at the bottom of the slope, and a cover formwork is installed above the steel reinforcement skeleton of the slope, so that the cover formwork and the base formwork form an enclosed space for concrete pouring. Concrete pouring: Concrete is poured into the enclosed space along the slope direction; Vibration compaction: Vibration devices are inserted into the concrete within the enclosed space through vibration operation holes opened on the cover mold to compact the concrete. The enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope.

2. The method for pouring concrete on a slope according to claim 1, characterized in that, The cover mold is assembled from multiple modular template units, which are fixedly connected by connectors.

3. The method for pouring concrete on a slope according to claim 1, characterized in that, The vibration operation hole includes a vibration hole and a vibration groove, both of which are formed on the cover mold; The vibratory grooves are arranged longitudinally along the slope on the cover mold, serving as material discharge holes and auxiliary vibration channels; the vibratory holes and vibratory grooves together constitute a synergistic vibration system.

4. The method for pouring concrete on a slope according to claim 3, characterized in that, The vibratory holes are arranged in a rectangular array on the cover mold with a row spacing of 80cm and a column spacing of 80cm; the vibratory grooves are set every 3-5 meters, with a width of 30-50cm.

5. The method for pouring concrete on a slope according to claim 1, characterized in that, The template construction also includes: setting short side wall templates on both longitudinal sides of the cover mold, the short side wall templates being used to form the lateral boundaries of the concrete pouring; The bottom plane of the short side wall formwork is provided with a serrated groove. The spacing of the serrated groove matches the spacing of the reinforcing bars in the structure to be poured. This is used to insert the reinforcing bars into the serrated groove, thereby simultaneously restricting the planar position of the reinforcing bars and fixing the short side wall formwork to the reinforcing bars, thus realizing the integration of formwork fixing and reinforcing bar limiting.

6. The method for pouring concrete on a slope according to claim 1, characterized in that, In the template construction step, the material of the cover mold is selected differently according to the required number of times the template is reused: bamboo plywood is used when reused 1-2 times, plastic template is used when reused 3-10 times, and aluminum template is used when reused more than 10 times.

7. The method for pouring concrete on a slope according to claim 1, characterized in that, In the template construction step, BIM model is used to design the template unit size, vibration hole position and joint position of the cover formwork, so that the vibration hole avoids the position of the steel reinforcement in the structure to be poured, and eliminates the interference between the joints between template units and the steel reinforcement. A test section with the same slope as the slope was built on the ground. Bamboo plywood and square timber were used for template assembly, reinforcement and simulated vibration to verify the rigidity, stability and feasibility of vibration operation of the template system, and to retain construction parameters.

8. The method for pouring concrete on a slope according to claim 1, characterized in that, The cover mold is fixed by a support system, which includes: aluminum square tube back ribs set on the back of the cover mold, with a spacing of 30cm between adjacent back ribs; a double-ply φ48×3.5mm steel pipe set every 90cm along the direction perpendicular to the back ribs; tie rods arranged in a 90cm×90cm grid pattern, the tie rods being welded to the pre-embedded steel bars, the pre-embedded steel bars being welded to the bottom plate steel bar skeleton; and thickened aluminum blocks being welded to the edges of the vibrating holes.

9. The method for pouring concrete on a slope according to claim 1, characterized in that, In the concrete pouring process, the concrete is poured in sections from bottom to top along the slope, with each section being 3-5m long. The interval between each section is less than or equal to the initial setting time of the concrete. After pouring, the concrete is covered with geotextile and watered for curing before initial setting, with a curing time of 14 days or more.

10. The method for pouring concrete on a slope according to claim 1, characterized in that, In the compaction step, the vibrating device is inserted to a depth of 50mm below the surface of the lower concrete layer, and the vibration time is 20-30s until the concrete surface no longer sinks, no air bubbles emerge, and a uniform slurry appears.

11. The method for pouring concrete on a slope according to any one of claims 1-10, characterized in that, It also includes curing and formwork removal: the cover formwork is removed when the concrete strength reaches 50% of the design strength, part of the support system is removed when it reaches 75%, and the entire support system is removed when it reaches 100%. The removal sequence is carried out in sections from top to bottom, and the length of each section is ≤3m.

12. A formwork system for pouring concrete on slopes, characterized in that, include: The base formwork is laid at the bottom of the slope; The cover formwork is set above the steel reinforcement skeleton of the slope, forming an enclosed space with the base formwork for concrete pouring; A vibration operation hole is provided on the cover mold for inserting the vibration device and venting air. The enclosed space is a closed or semi-closed space used to constrain the flow of concrete on the slope.

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