Fabricated concrete pipe gallery design and construction method

Abstract

The application relates to a design and construction method of an assembled concrete pipe gallery. The construction method comprises the following steps: S1, prefabricating a concrete column and a concrete beam, the end of the concrete beam is reserved with exposed beam end steel bars, and the connecting side surface of the concrete column is embedded with protruding column side steel bars; S2, hoisting the concrete column, anchoring the lower end of the concrete column in the bearing platform foundation, and adjusting and fixing the verticality and elevation; S3, installing an independent temporary support structure between two adjacent installed concrete columns; S4, hoisting the concrete beam, erecting the two ends of the concrete beam on the temporary support structure, and cross-over arranging the beam end steel bars and the column side steel bars to form a steel bar connecting joint; the application greatly reduces high-altitude operation and the use of a scaffold, the main operation is completed on the ground or at low altitude, the safety risk is reduced, prefabrication and installation can be carried out in a flow, and the construction period is significantly shortened.

Description

Technical Field

[0001] This invention belongs to the field of building engineering technology, and specifically relates to a design and construction method for prefabricated concrete pipe gallery. Background Technology

[0002] Traditional cast-in-place concrete pipe gallery construction typically involves tying reinforcing bars, erecting scaffolding and formwork on-site, and then pouring concrete layer by layer. This method suffers from problems such as long construction cycles, the need for large amounts of scaffolding materials and labor, numerous high-altitude operations, high safety risks, long construction site occupancy times, and the inability to achieve streamlined operations, which severely restricts construction efficiency and increases costs.

[0003] To overcome the aforementioned drawbacks, existing technologies have employed partial prefabrication methods, such as using "gate"-shaped monolithic prefabricated components. However, this method results in massive volumes and weights of prefabricated components, significantly increasing the difficulty and cost of transportation and hoisting. Furthermore, the remaining unprefabricated beams still require extensive on-site formwork and pouring work, failing to completely eliminate reliance on scaffolding and high-altitude operations. Another improvement is the use of bolted sleeves to connect prefabricated beams and columns, but this method suffers from challenges such as difficulty in ensuring the density of grouting within the sleeves, questionable connection reliability, and the high cost of the bolts and sleeves themselves.

[0004] Therefore, there is an urgent need for a prefabricated concrete pipe gallery design and construction method that can significantly reduce on-site high-altitude operations and scaffolding usage, ensure reliable connections, facilitate convenient and efficient construction, and reduce overall costs. Summary of the Invention

[0005] The purpose of this invention is to provide a design and construction method for prefabricated concrete pipe corridors in order to solve the problems mentioned in the background art.

[0006] The present invention achieves the above objectives through the following technical solutions: A design and construction method for prefabricated concrete pipe gallery includes the following steps: S1: Precast concrete columns and concrete beams, wherein exposed beam end reinforcement is reserved at the ends of the concrete beams, and protruding column side reinforcement is embedded on the connecting side of the concrete columns. S2: Hoist the concrete column, anchor its lower end in the foundation, and adjust and fix its verticality and elevation; S3: Install independent temporary support structures between two adjacent installed concrete columns; S4: Hoist the concrete beam and place both ends of it on the temporary support structure, and arrange the beam end reinforcement and the column side reinforcement to cross and overlap to form a reinforcement connection node; S5: Set up a node formwork at the rebar connection node, pour concrete, and form a fixed integral node.

[0007] Preferably, in step S1, when the concrete column is prefabricated, the column side reinforcement is arranged in two rows, and the spacing between the two rows of column side reinforcement is smaller than the spacing between the two rows of beam end reinforcement at the end of the concrete beam, so that the beam end reinforcement can surround the column side reinforcement from the outside during hoisting.

[0008] Preferably, in step S2, the concrete column is roughened before being inserted into the foundation, and the roughening depth is not less than 6mm.

[0009] Preferably, in step S4, a pad is provided between the top of the temporary support structure and the bottom of the concrete beam to provide operating space for formwork and pouring operations at the node.

[0010] Preferably, the pad is a channel steel, with its opening facing downwards and upside down on top of the temporary support structure.

[0011] Preferably, the temporary support structure includes vertically arranged adjustable support columns and support beams connected to their tops.

[0012] Preferably, in step S4, multiple concrete beams are clamped simultaneously using a clamping mechanism; The clamping mechanism includes an outer frame and several clamping components equidistantly spaced on the outer frame for clamping concrete beams.

[0013] Preferably, the clamping member includes a placement platform, a hook rotatably connected to the placement platform, and a first telescopic member disposed on the placement platform for driving the hook to rotate to move the concrete beam onto the placement platform; The placement platform is rotatably connected to the outer frame.

[0014] Preferably, two expansion joints are fixedly installed on the outer frame, and the expansion ends of the two expansion joints are provided with adjustment blocks that contact the concrete columns to adjust the position of the outer frame.

[0015] The beneficial effects of this invention are as follows: 1. This invention greatly reduces the use of high-altitude operations and scaffolding, with the main operations completed on the ground or at low altitudes, thus reducing safety risks; prefabrication and installation can be carried out in an assembly line, significantly shortening the construction period.

[0016] 2. The present invention adopts the method of cross-lapped reinforcement and subsequent concrete pouring, which has the same stress performance as traditional cast-in-place joints, and the connection quality is easy to guarantee, overcoming the hidden dangers such as incomplete grouting of sleeves.

[0017] 3. In this invention, beams and columns are prefabricated separately, reducing weight and lowering the difficulty and cost of hoisting. The optimized spacing design of the joint reinforcement (beam reinforcement spacing is slightly larger than column reinforcement spacing) enables rapid, enclosed alignment, facilitating installation. Since the components are prefabricated in the factory, their quality is far superior to on-site work.

[0018] 4. This invention significantly reduces scaffolding rental fees and labor costs for erection and dismantling; the temporary support system can be standardized in design and reused repeatedly, resulting in low amortization costs; and the shortened construction period leads to a reduction in overall management costs.

[0019] 5. This invention eliminates the need for large-scale scaffolding, freeing up construction space and facilitating simultaneous and cross-operations on multiple work surfaces. It is particularly suitable for renovation or expansion projects with limited space.

[0020] 6. The multi-beam synchronous clamping and hoisting mechanism of this invention enables the hoisting and installation of multiple concrete beams in a single operation, breaking through the efficiency bottleneck of traditional single-beam hoisting.

[0021] 7. The hoisting mechanism of this invention has an active stabilization system based on telescopic components and slots, which can quickly lock with the installed column, greatly reducing the swaying of the components at high altitudes and avoiding the risk of manual high-altitude intervention and adjustment. Attached Figure Description

[0022] Figure 1 This is a flowchart of the method of the present invention; Figure 2 This is a schematic diagram showing the overall effect of the prefabricated concrete pipe gallery after construction in this invention; Figure 3 yes Figure 2 Enlarged view of point A in the middle; Figure 4 This is an exploded view of the prefabricated concrete pipe gallery structure after construction in this invention; Figure 5 This is a schematic diagram showing the positional relationship between the concrete column and the foundation cap in this invention; Figure 6 This is a schematic diagram of the clamping mechanism in this invention; Figure 7 This is a second-view structural schematic diagram of the clamping mechanism in this invention; Figure 8 This is a right view of the clamping mechanism in this invention; Figure 9 This is a schematic diagram of the on-site construction of the prefabricated concrete pipe gallery in this invention.

[0023] In the diagram: 1. Concrete column; 2. Concrete beam; 3. Beam end reinforcement; 4. Column side reinforcement; 5. Foundation; 6. Pad block; 7. Adjustable support column; 8. Support beam; 9. Outer frame; 10. Placement platform; 11. Hook; 12. No. 1 expansion joint; 13. No. 2 expansion joint; 14. Adjustment block; 15. Bottom inclined column; 16. Slot; 17. Hook. Detailed Implementation

[0024] The present application will now be described in further detail. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content. Example 1

[0025] like Figure 1-9 As shown, a design and construction method for prefabricated concrete pipe gallery includes the following steps: S1: Concrete column 1 and concrete beam 2 are cast separately at the factory or prefabrication yard. For concrete beam 2, no concrete is poured within approximately 300mm of both ends, leaving the beam end reinforcement 3 exposed. For concrete column 1, column side reinforcement 4 protruding from the surface of the concrete column 1 is pre-embedded on its side at a predetermined height (beam bottom elevation). The key design feature is that the column side reinforcement 4 is divided into two rows, upper and lower, with a spacing slightly smaller than the spacing between the upper and lower rows of beam end reinforcement 3 at the ends of concrete beam 2. This design allows the concrete beam 2 end reinforcement to surround the column side reinforcement 4 during hoisting and lowering, achieving rapid alignment.

[0026] S2: Hoist the concrete column 1, anchoring its lower end within the foundation 5, and adjust and secure its verticality and elevation. Before inserting the concrete column into the foundation 5, roughen the insertion portion to a depth of at least 6mm to ensure contact quality for subsequent grouting. Before hoisting the concrete column 1, pre-fix the guy ropes to the top and pre-adjust the installation elevation using grout. During installation, use chain hoists, guy ropes, and shims for fine-tuning to ensure the column's horizontality, verticality, and elevation. Grouting will proceed after acceptance.

[0027] S3: Install an independent temporary support structure between two adjacent installed concrete columns 1. The temporary support structure includes a vertically arranged adjustable support column 7, a support beam 8 fixedly connected to its top, and a bottom inclined column 15 for supporting the support beam 8. The adjustable support column 7, the support beam 8, and the bottom inclined column 15 form a triangular structure, wherein the adjustable support column 7 and the support beam 8 are perpendicular to each other.

[0028] A spacer block 6 is provided between the top of the temporary support structure and the bottom surface of the concrete beam 2 to provide operating space for formwork and pouring operations at the joint. The spacer block 6 is a channel steel, with its opening facing downwards and upside down on the top of the temporary support structure.

[0029] S4: Hoist the concrete beam 2 and place both ends of it on the temporary support structure, and arrange the beam end steel bars 3 and the column side steel bars 4 to cross and overlap to form a steel bar connection node; S5: Set up a node formwork at the rebar connection node, pour concrete, and form a fixed integral node. Example 2

[0030] When installing concrete beam 2, only one beam can be installed at a time, resulting in low installation efficiency.

[0031] To further improve construction efficiency, a clamping mechanism is used to clamp multiple concrete beams simultaneously.

[0032] The clamping mechanism includes an outer frame 9 and several clamping components equidistantly spaced on the outer frame 9 for clamping the concrete beam 2. A hook 17 is fixedly provided on the top of the outer frame 9, and the outer frame 9 can be lifted by using a crane to hook the hook 17.

[0033] The clamping components include a placement platform 10, a hook 11 rotatably connected to the placement platform 10, and a first telescopic component 12 mounted on the placement platform 10 for rotating the hook 11 to move the concrete beam 2 onto the placement platform 10. The placement platform 10 is rotatably connected to the outer frame 9. The first telescopic component 12 is a hydraulic cylinder or an electric push rod.

[0034] It should be noted that when placing the concrete beam 2 on the ground, wooden blocks can be used to elevate it. The crane drags the outer frame 9 to the concrete beam 2, and slowly lowers the outer frame 9, causing the clamping parts to rotate relative to the outer frame 9. After the outer frame 9 is lowered, the bottom of the platform 10 contacts the ground.

[0035] The first telescopic component 12 is rotatably mounted on the placement platform 10 and the hook 11 at both ends, respectively. When the first telescopic component 12 shortens, the hook 11 rotates relative to the placement platform 10, thereby pushing the concrete beam 2 located on the ground toward the placement platform 10 and eventually moving it into the placement platform 10. The placement platform 10 has an L-shaped structure, with the main body of the concrete beam 2 entering the placement platform 10 and both ends of the concrete beam 2 located outside the placement platform 10.

[0036] Next, the crane lifts the top of the outer frame 9 away from the ground, making the outer frame 9 stand upright and gradually move it away from the ground. The outer frame 9 moves to the corresponding position of the concrete column 1, so that the concrete beam 2 is directly above the temporary support structure. By hooking and reversing the movement to release the concrete beam 2, the outer frame 9 can be moved laterally or downward to detach the placement platform 10 from the concrete beam 2, completing the placement of the concrete beam 2.

[0037] Multiple concrete beams 2 can be placed parallel to each other on the ground simultaneously, and multiple clamping devices can clamp the concrete beams 2, allowing for the simultaneous installation of multiple concrete beams 2. Example 3

[0038] When installing the concrete beam 2, ropes are typically used to tie both ends of the beam, and a crane is used to lift the ropes and the concrete beam 2 simultaneously. The concrete beam 2 sways in the air, requiring manual or external force to adjust its position, which is not only cumbersome but also somewhat dangerous. To solve this problem, two expansion joints 13 are fixedly installed on the outer frame 9. Each expansion joint 13 has an adjustment block 14 at its extension end that contacts the concrete column 1 to adjust the position of the outer frame 9.

[0039] It should be noted that when the outer frame 9 moves between the concrete columns 1 and the concrete column 1, the second expansion joint 13 extends, causing the adjusting block 14 to move towards the concrete column 1. The adjusting block 14 has a slot 16, which engages with the concrete column 1 to limit the movement of the outer frame 9, thus preventing it from swaying. Using a crane to adjust the height of the outer frame 9 eliminates the need for manual adjustment of the concrete beam 2, reducing the likelihood of accidents.

[0040] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A design and construction method for prefabricated concrete pipe gallery, characterized in that, Includes the following steps: S1: Precast concrete column (1) and concrete beam (2), the ends of the concrete beam (2) are reserved with exposed beam end steel bars (3), and the connecting side of the concrete column (1) is pre-embedded with protruding column side steel bars (4). S2: Hoist the concrete column (1) so that its lower end is anchored in the foundation (5) and adjust and fix its verticality and elevation; S3: Install independent temporary support structures between two adjacent installed concrete columns (1); S4: Hoist the concrete beam (2), place both ends of it on the temporary support structure, and make the beam end steel bars (3) and the column side steel bars (4) cross and overlap to form a steel bar connection node; S5: Set up a node formwork at the rebar connection node, pour concrete, and form a fixed integral node.

2. The design and construction method for prefabricated concrete pipe gallery according to claim 1, characterized in that, In step S1, when the concrete column (1) is prefabricated, the column side reinforcement (4) embedded on its side is arranged in two rows, and the spacing between the two rows of column side reinforcement (4) is smaller than the spacing between the two rows of beam end reinforcement (3) at the end of the concrete beam (2), so that the beam end reinforcement (3) can surround the column side reinforcement (4) from the outside when hoisting.

3. The design and construction method for prefabricated concrete pipe gallery according to claim 1, characterized in that, In step S2, the concrete column (1) is roughened before being inserted into the foundation (5), and the roughening depth is not less than 6mm.

4. The design and construction method for a prefabricated concrete pipe gallery according to claim 1, characterized in that, In step S4, a pad (6) is provided between the top of the temporary support structure and the bottom of the concrete beam (2) to provide operating space for formwork and pouring operations at the node.

5. The design and construction method for a prefabricated concrete pipe gallery according to claim 4, characterized in that, The pad (6) is a channel steel, with its opening facing downwards and upside down on the top of the temporary support structure.

6. The design and construction method for a prefabricated concrete pipe gallery according to claim 5, characterized in that, The temporary support structure includes vertically arranged adjustable support columns (7) and support beams (8) connected to their tops.

7. The design and construction method for a prefabricated concrete pipe gallery according to claim 1, characterized in that, In step S4, multiple concrete beams (2) are clamped simultaneously using a clamping mechanism. The clamping mechanism includes an outer frame (9) and a number of clamping components that are equidistantly arranged on the outer frame (9) for clamping the concrete beam (2).

8. The design and construction method for a prefabricated concrete pipe gallery according to claim 7, characterized in that, The clamping component includes a placement platform (10), a hook (11) rotatably connected to the placement platform (10), and a first telescopic component (12) provided on the placement platform (10) for driving the hook (11) to rotate and move the concrete beam (2) onto the placement platform (10). The placement platform (10) is rotatably connected to the outer frame (9).

9. The design and construction method for a prefabricated concrete pipe gallery according to claim 8, characterized in that, Two No. 2 telescopic components (13) are fixedly installed on the outer frame (9). The telescopic ends of the two No. 2 telescopic components (13) are provided with adjustment blocks (14) that contact the concrete column (1) to adjust the position of the outer frame (9).

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