Bridge building machine with zenith crane and construction method thereof
By designing a bridge-building machine with a zenith crane, the steel reinforcement is hoisted as a whole using the track beam and hook, solving the problem of inconvenient steel reinforcement hoisting in the upper-bearing bridge-building machine, improving construction efficiency and overall stability, and is suitable for application in large-segment cantilever cast-in-place continuous beam construction sites.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- CHINA RAILWAY NO 2 ENG GROUP CO LTD
- Filing Date
- 2026-06-25
- Publication Date
- 2026-07-31
AI Technical Summary
Existing bridge-building machines with upper-bearing structures have problems with the inconvenience of hoisting steel bars during construction, and their overall stability and load-bearing capacity are limited. They are particularly uncommon in applications involving large-segment cantilever cast-in-place continuous beams.
Design a bridge-building machine with a zenith crane. By setting up a track beam and hook to form a zenith crane structure, the track beam and hook are used to hoist the reinforcing steel as a whole. Combined with a suspension system, a formwork system and a rear anchor, the machine can quickly install and hoist the reinforcing steel as a whole.
It increased the speed of steel bar installation, reduced on-site binding time, improved construction efficiency, and enhanced the overall stability and load-bearing capacity of the bridge-building machine.
Smart Images
Figure CN122485175A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of bridge building machines, and in particular to a bridge building machine with a zenith crane and its construction method. Background Technology
[0002] Currently, bridge-building machines mainly used in bridge construction can be divided into two categories: upper-bearing bridge-building machines and lower-bearing bridge-building machines. The force mechanism of upper-bearing bridge-building machines is similar to that of ordinary triangular or diamond-shaped hanging baskets, primarily relying on the web to bear the load. The lateral connections between the main trusses are strong, resulting in good overall stability. In contrast, the load-bearing components of lower-bearing bridge-building machines are located below the flanges. The reaction force of the rear main truss acts on the flanges through slings, but the local bearing capacity of the flanges is relatively weak, thus limiting the load-bearing capacity of this type of bridge-building machine. Furthermore, due to structural space constraints, the lateral connection between the two main trusses is weak, leading to poor overall stability and lower versatility for later reuse. Comprehensive analysis suggests that upper-bearing bridge-building machines are more suitable for the widespread application of large-segment cantilever continuous beam construction. However, in practical applications, it has been found that upper-bearing bridge-building machines present challenges in hoisting materials such as reinforcing bars during construction. Summary of the Invention
[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a bridge-building machine with a zenith crane and its construction method.
[0004] In a first aspect, the present invention provides a bridge-building machine with a zenith crane, comprising a track beam, a gantry, a main beam, a crossbeam, hanging legs, a bottom formwork platform, a suspension system, a formwork system, a rear anchor, a traveling system, a tensioning platform, a hydraulic control system, an electrical system, and a safety protection system;
[0005] Two track beams are spaced apart and connected by a gantry, which is located above the track beams. The track beam is equipped with hooks to form a ceiling-mounted structure. After the previous section of steel reinforcement is tied up, the entire structure can be hoisted into the formwork system using the track beam and hooks. The main beam is located below the track beam, and the two main beams are spaced apart. The track beam and the main beam are connected by diagonal and vertical braces. The crossbeam is bolted to the main beam, and the hanging leg is located below the crossbeam and bolted to the crossbeam. It is used to support the rear support point of the outer formwork longitudinal beam and to suspend the rear hanger of the bottom formwork platform in the traveling state. The bottom formwork platform is used to directly bear the weight of the concrete bottom slab and web of the beam segment, and to provide an operating area for formwork erection and concrete pouring. The suspension system includes front and rear hangers of the bottom formwork platform, front hangers of the outer formwork longitudinal beam, and front and rear hangers of the inner formwork longitudinal beam. The front and rear hangers of the bottom formwork platform are connected to the crossbeam and are used to suspend the bottom formwork platform. The front hangers of the outer formwork longitudinal beam are connected to the crossbeam and are used to suspend the front end of the outer formwork longitudinal beam. The front hangers of the inner formwork longitudinal beam are connected to the crossbeam. The rear hangers of the inner formwork longitudinal beam are connected to the top plate of the box girder. The front and rear hangers of the inner formwork longitudinal beam are used to suspend the inner formwork longitudinal beam. The template system includes an outer template and an inner template. The outer template consists of a web template and a flange template. The outer template longitudinal beams are used to support the outer template. The inner template consists of an inner template, an inner template frame, and an upper crossbeam. The inner template longitudinal beams are used to support the inner template, and the outer template longitudinal beams are used for support and also serve as sliding beams during travel. The rear anchor is used to balance the overturning moment of the main beam while the concrete is being poured.
[0006] Preferably, the hanging legs include front hanging legs and rear hanging legs arranged at intervals.
[0007] Preferably, in the concrete pouring state, the front end of the bottom formwork platform is suspended on the front crossbeam by the front hanger of the bottom formwork platform, and the rear end is anchored to the bottom plate and flange plate of the formed beam segment by the side rear hanger of the bottom formwork platform. In the traveling state, the rear end of the bottom formwork platform is suspended on the hanging leg by the side rear hanger of the bottom formwork platform.
[0008] Preferably, the front and rear suspension rods of the bottom formwork platform adopt a combination of sling units and rod units, the upper lifting section adopts screw rods, and the lower fixed section and adjusting section adopt steel plate slings.
[0009] Preferably, the connection between the sling units and the connection between the sling unit and the boom unit are made by bolts.
[0010] Preferably, the front end of the outer mold longitudinal beam is suspended on the front cross beam, and the rear end is supported on the hanging leg by a screw.
[0011] Preferably, the rear anchor is an anchor plate type rear anchor, and the traveling system adopts a walking-type travel.
[0012] In a second aspect, the present invention provides a construction method for a bridge-building machine with a zenith crane, employing any of the bridge-building machines with zenith cranes described above, comprising the following steps: S1: Install the bridge-building machine; S2: Conduct a bridge-building machine loading test; S3: Beam segment formwork installation, rebar tying, and prestressed duct installation; After the beam reinforcement is tied as a whole in the previous segment, it is hoisted into the formwork using a track beam and hook; the bottom plate, web plate and transverse diaphragm are installed, and then the top plate reinforcement is installed. The reinforcement installation is carried out simultaneously with the prestressed duct installation. S4: Pouring concrete; S5: Concrete curing; S6: Prestressed tensioning and duct grouting; S7: Anchor sealing.
[0013] Preferably, the construction method further includes: S8: The bridge-building machine moves to the next segment; S9: Repeat steps S3-S8 until all symmetrical cantilever grouting sections are completed.
[0014] Preferably, the construction method further includes: S10: Dismantle the bridge-building machine; S11: Construction of the closure section.
[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention provides a bridge-building machine with a zenith crane and its construction method. By setting up a track beam and a hook, a zenith crane structure is formed. After the previous section of steel reinforcement is tied as a whole, the entire machine is hoisted into the formwork system using the track beam and hook. This can speed up the installation of steel reinforcement, reduce the time required for on-site tying of steel reinforcement in the formwork, and improve the construction efficiency of the bridge-building machine. Attached Figure Description
[0016] Figure 1 This is a front view of a bridge-building machine with a zenith crane according to the present invention.
[0017] Figure 2 This is a side view of a bridge-building machine with a zenith crane according to the present invention.
[0018] Figure 3 This is a schematic diagram of the gantry structure described in this invention.
[0019] Figure 4 This is a front view of the hanging leg described in this invention.
[0020] Figure 5 This is a side view of the hanging leg described in this invention.
[0021] Figure 6 This is a front view of the front suspension rod of the bottom mold platform described in this invention.
[0022] Figure 7 This is a side view of the front suspension rod of the bottom mold platform described in this invention.
[0023] Figure 8 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 1 .
[0024] Figure 9 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 2 .
[0025] Figure 10 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 3 .
[0026] Figure 11 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 4 .
[0027] Figure 12 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 5 .
[0028] Figure 13 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 6 .
[0029] Figure 14 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 7 .
[0030] Figure 15 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 8 .
[0031] Figure 16 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 9 .
[0032] Figure 17 This is a schematic diagram of the installation method of the bridge-building machine described in this invention. Figure 10 .
[0033] Marked in the image: 1-Hanging leg, 11-Front hanging leg, 12-Rear hanging leg, 2-Main beam, 3-Crossbeam, 4-Rail beam, 5-Gantry, 51-Stiffening plate, 6-Vertical rod, 7-Diagonal rod, 8-Suspension system, 81-Front hanger of bottom formwork platform, 811-Sling unit, 812-Hanger rod unit, 813-Connecting unit, 814-Conversion unit, 815-Spreader beam, 82-Rear hanger of bottom formwork platform, 83-Front hanger of outer formwork longitudinal beam, 84-Front hanger of inner formwork longitudinal beam, 85-Rear hanger of inner formwork longitudinal beam, 9-Bottom formwork platform, 91-Outer formwork, 92-Inner formwork, 921-Inner formwork longitudinal beam, 10-Hook, 13-Assembly bracket, 14-Loading test device. Detailed Implementation
[0034] The present invention will now be described in further detail with reference to specific embodiments. However, this should not be construed as limiting the scope of the present invention to the following embodiments; all technologies implemented based on the content of the present invention fall within the scope of the present invention.
[0035] Unless otherwise specified, the terms "upper," "lower," "left," "right," "center," "inner," and "outer," etc., used in the description of specific embodiments of the present invention to indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationship in which the product / equipment / device is usually placed during use. These terms are merely for the purpose of facilitating the description of the present invention or simplifying the description in specific embodiments, and for enabling those skilled in the art to quickly understand the solution, and do not indicate or imply that a particular device / component / element must have a specific orientation, or be constructed and operated in a specific positional relationship. Therefore, they should not be construed as limitations on the present invention.
[0036] Furthermore, the use of terms such as "horizontal," "vertical," "suspended," "parallel," and "coaxial" does not imply that the corresponding device / component / element must be absolutely horizontal, vertical, suspended, parallel, or coaxial. Slight tilt or deviation is permissible, as long as it does not affect the normal function of the relevant component. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," not that the structure must be perfectly horizontal; a slight tilt is acceptable. "Coaxial" means that two components are arranged as coaxially as possible, allowing them to move coaxially or approximately coaxially when their relative positions change. Alternatively, it can be simplified to mean that the corresponding device / component / element, when arranged in "horizontal," "vertical," "suspended," "parallel," or "coaxial" directions, can have an error / deviation of ±10% relative to the corresponding direction, more preferably within ±8%, more preferably within ±6%, more preferably within ±5%, and more preferably within ±4%. For example, the deviation in the "coaxial" direction is controlled within 0.2-1mm, preferably within 0.2-0.5mm. As long as the corresponding device / component / element is within the error / deviation range, it can still achieve its function in the solution of the present invention.
[0037] Furthermore, the use of terms such as "first," "second," and "third" in terminology is merely for distinguishing descriptions of identical or similar components and should not be interpreted as emphasizing or implying the relative importance of a particular component.
[0038] Furthermore, in the description of the embodiments of the present invention, "several", "more than", and "a number of" represent at least two. The number can be any number, such as two, three, four, five, six, seven, eight, or nine, and can even exceed nine.
[0039] Furthermore, in the description of the technical solution of this invention, unless otherwise explicitly specified / limited / restricted, the terms "set up," "install," "connect," "link," "provided with," "laid out," and "arranged" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to connection methods commonly used in the art, such as welding, riveting, bolting, and threaded connections. Such connections can be mechanical, electrical, or communication connections; they can be direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components.
[0040] Example 1 like Figures 1-2 As shown, a bridge-building machine with a zenith crane includes a track beam 4, a gantry 5, a main beam 2, a crossbeam 3, a hanging leg 1, a bottom formwork platform 9, a suspension system 8, a formwork system, a rear anchor, a traveling system, a tensioning platform, a hydraulic control system, an electrical system, and a safety protection system.
[0041] (1) Main Girder 2. The main girder 2 of the bridge-building machine is 19.6m long and is made in three sections in the factory: section A is 3.595m, section B is 7.99m, and section C is 7.995m. It adopts the form of a steel box girder, with a total height of 1.5m and a width of 1.1m. It is mainly made of Q235b and Q335b steel plates welded together. The sections of the main girder 2 are connected by high-strength bolts with splicing plates. The splicing plates are made of the same material as the main girder 2.
[0042] The main beam 2 is located below the track beam 4. The two main beams 2 are spaced apart, and the track beam 4 and the main beam 2 are connected by diagonal braces 7 and vertical braces 6.
[0043] (2) Track beam 4 and gantry 5. Two track beams 4 are spaced apart and connected by a gantry 5 located above the track beams 4. The track beam 4 is 27m long and is divided into five sections manufactured in the factory: section A (3.995m), section B (3.99m), section C (7.99m), section D (7.99m), and section E (2.995m). It adopts the form of a steel box girder, with a total beam height of 1m and a beam width of 1.1m, mainly welded from Q235b and Q335b steel plates. Figure 3 As shown, the gantry 5 is composed of Q235 H700×200×12×20 (double H-beams) and stiffening ribs, with a length of 10.56m. The stiffening plate 51 is composed of Q235b d16 steel plates and is connected to the track beam 4 with high-strength bolts.
[0044] The track beam 4 is equipped with a hook 10 to form a ceiling-mounted structure. After the previous section of steel reinforcement is tied, the track beam 4 and the hook 10 can be used to hoist the entire structure into the formwork system.
[0045] (3) Crossbeam 3 and hanging leg 1 The crossbeam 3 is bolted to the main beam 2, and the hanging leg 1 is located below the crossbeam 3. The crossbeam 3 is composed of HN606x201x12x20 (double-layered) steel plates and stiffening ribs. The stiffening ribs are made of δ20 and δ16 steel plates, with a cross-section height of 606mm, a width of 402mm, a flange thickness of 20mm, and a web thickness of 12mm. The crossbeam 3 is 2.75m long and is connected to the main beam 2 using high-strength bolts.
[0046] like Figures 4-5 As shown, the hanging leg 1 includes a front hanging leg 11 and a rear hanging leg 12 spaced apart. The hanging leg 1 is composed of HN606x201x12x20 (double-layered) steel and stiffening ribs. The stiffening ribs are made of δ30, δ20, and δ16 steel plates. It is connected to the crossbeam 3 with high-strength bolts. Its function is to support the rear support point of the outer formwork longitudinal beam and suspend the rear suspension rod 82 of the bottom formwork platform in the traveling state.
[0047] (4) Rear Anchor The rear anchor is used to balance the overturning moment of the main beam 2 during concrete pouring. It consists of a rear anchor beam 3, a pad plate, a hydraulic cylinder spreader beam 815, a lifting hydraulic cylinder, the rear anchor spreader beam 815, anchor rods, and wedge blocks. The rear anchor beam 3 is welded from Q335b steel plates, with a length of 10300mm and a width of 500mm. The pad plate is made of Q235 steel plate, with a length of 200mm, a width of 200mm, and a thickness of 30mm. The hydraulic cylinder spreader beam 815 is welded from steel plates, with a length of 700mm and a width of 220mm. The rear anchor spreader beam 815 is welded from Q235b steel plates, with a length of 1900mm and a width of 330mm.
[0048] (5) Running system The running system includes a front support, rollers, rear outriggers, running beam, anchor beam, lifting cylinder, lifting frame, traction cylinder, traction rod, and reaction seat.
[0049] The front support serves as the front support point of the main beam 2 during concrete pouring and also acts as a front reaction seat to fix the traction cylinders during travel. The front support is a box-shaped structure welded from steel plates, with lateral limiting rollers on both sides to prevent the main beam 2 from shifting laterally during travel. There are two lateral installation positions for the traction cylinders. During normal travel, the traction cylinder is installed in the middle. When the main beam 2 shifts, the cylinder is moved to the installation position on the offset side to correct the deviation.
[0050] Rollers are used to balance the overturning moment of the main beam 2 during travel. Two reverse-clamping rollers are installed on each side of the main beam 2, fastened to the lower flange plate. The rollers are pin-connected to the roller frame, and the roller frame is connected to the traveling beam using high-strength bolts. The roller reaction force transmission path is: lower flange of the box girder → roller → roller frame → traveling beam → anchor beam → anchor bolt → box girder.
[0051] The rear outrigger is installed at the rear end of the main beam 2, with its upper end pinned to the lower flange of the main beam 2 and its lower end supported on the top surface of the box girder. In the forward-moving state of the traveling beam, it serves as a safety support for the main beam 2 in the opposite direction of overturning.
[0052] Anchor beams and anchor rods are used to reliably anchor the traveling beams to the top surface of the box girder.
[0053] The traction cylinder adopts a 100-ton through-type intelligent digital cylinder, which is centrally controlled by a 30-channel PLC intelligent synchronous control system to ensure that the two main beams move synchronously and prevent lateral deviation.
[0054] The traction rod is a Q355 grade Ф70mm through rod, with the front end anchored to the traction cylinder and the rear end anchored to the reaction seat welded to the bottom of the main beam.
[0055] The jacking system mainly consists of components such as jacking frame, jacking cylinder, rail beam, anti-locking wheel, rear roller, track, sleeper, front support, and pad.
[0056] The lifting frame is a portal-shaped structure welded from Q235b steel plates, measuring 2780×2460×400mm in length, height, and width. The primary lifting cylinder is 100t (100mm stroke), and the secondary lifting cylinder is 150t (100mm stroke). The rail beam is a combined structure welded from No. 28 slotted steel plates, measuring 1500×280×238mm in length, height, and width. The reverse-locking wheel is a combination of rollers and ear plates.
[0057] The running track is made of Q235b flange, web, connecting plate and neck plate welded together, with a length, height and width of 10750×500×250mm.
[0058] (6) Bottom mold platform 9 The bottom formwork platform 9 directly bears the weight of the concrete bottom slab and web of the beam segment and provides an operating area for processes such as formwork erection and concrete pouring. It consists of bottom crossbeams 3, side rear hanging frames, formwork, longitudinal beams, and front and rear crossbeams 3.
[0059] The bottom formwork uses large steel formwork panels. There are two types of longitudinal beams: Longitudinal beam A consists of four fish-belly type steel plate beams welded together, located under the side webs of the box girder and connected to the front and rear crossbeams (3) with high-strength bolts. Longitudinal beam B consists of two H-beams (H650x300x11x17), located under the bottom plate of the box girder and connected to the front and rear crossbeams (3) with high-strength bolts. Crossbeams (3) are box girders welded together from 2HN606x201x12x20 H-beams with high torsional stiffness. The center distance between the front and rear crossbeams (3) is 9800mm.
[0060] In the concrete pouring state, the front end of the bottom formwork platform 9 is suspended from the front crossbeam 3 by the front sling, and the rear end is anchored to the bottom plate and flange plate of the completed beam segment by the rear hanger. In the traveling state, the rear end of the bottom formwork platform 9 is suspended from the hanging leg 1 by the side rear hanger.
[0061] (7) Suspension system 8 The suspension system 8 includes front and rear suspension rods of the bottom formwork platform, front suspension rod 83 of the outer formwork longitudinal beam, and front and rear suspension rods of the inner formwork longitudinal beam.
[0062] like Figures 6-7 As shown, the front and rear suspension rods of the bottom formwork platform include a front suspension rod 81 and a rear suspension rod 82. The front suspension rod 81 of the bottom formwork platform adopts a combination of a sling unit 811 and a rod unit 812. The upper lifting section uses a screw, and the lower fixed section and adjusting section use steel plate slings.
[0063] Furthermore, the upper lifting section uses a Q460b M72x6 threaded rod with good cold bending performance, while the lower fixed and adjusting sections use 50mm thick Q355b steel plate slings with a width of 160mm. The upper end of the boom unit 812 is equipped with a spreader beam 815, and the lower end of the sling unit 811 is pinned to the crossbeam 3. The sling units 811 are connected to each other via connecting units 813, and the sling units 811 are connected to the boom unit 812 via conversion units 814. Preferably, high-strength bolts are used to connect the sling units 811 and the sling units 811 to the boom unit 812.
[0064] The upper end of the boom is supported on the front crossbeam 3 by a hydraulic cylinder and a nut. The hydraulic cylinder is a mechanically self-locking through-type intelligent digital hydraulic cylinder, centrally controlled by a 30-channel intelligent synchronous control system of PLC. The hydraulic cylinder has a central hole base, on which a safety nut is installed.
[0065] The bottom formwork platform's rear suspension rod 82 uses a Q460b M72x6 threaded rod. Its lower end is pinned to the crossbeam 3 via a lifting lug, and its upper end is supported on the box girder's bottom plate and flange plate via a spreader beam 815 and hydraulic cylinders. The hydraulic cylinders are mechanically self-locking intelligent digital cylinders, centrally controlled by a 30-channel PLC intelligent synchronous control system. Safety nuts are installed on the top surface of the box girder and the top surface of the flange plates.
[0066] The front hangers 83 of the outer mold longitudinal beam and the front and rear hangers 921 of the inner mold longitudinal beam are all made of Φ60mm Q345b round steel with good cold bending performance, and are equipped with T56x4 screws at the upper end.
[0067] The front and rear hangers of the inner formwork longitudinal beam include a front hanger 84 and a rear hanger 85. The front hanger 84 is connected to the crossbeam 3, and the rear hanger 85 is connected to the top plate of the box girder. The front and rear hangers are used to suspend the inner formwork longitudinal beam 921.
[0068] (8) The template system includes an outer mold and an inner mold 92 ①The outer mold consists of a web template and a flange template.
[0069] The flange plate template has a width and height of 4200 mm. The 1200mm large steel formwork is 8.4m long and 12.7m high. The formwork panel is made of 5mm Q235 steel plate, the horizontal ribs are made of Q235b 8# channel steel, the end horizontal ribs and side vertical ribs are made of Q235b 12mm steel plate, and the stiffening ribs are made of 5mm Q235 steel plate.
[0070] As the height of each segment decreases, the web height adjustment template is 2 meters high, with the lowest segment being 1.5 meters. The template is 4200 mm long. 2000, 2100 2000, 4200 1500, 2100 There are four types of templates, and the templates are connected with high-strength bolts.
[0071] The longitudinal beams are used to support the outer formwork. They consist of two H-beams, each 10.8m long and 1.15m apart. The front end is suspended from the front crossbeam 3, and the rear end is supported on the hanging leg 1 by a screw rod.
[0072] ② The inner mold 92 consists of the inner mold 92 plate, the inner mold 92 frame, and the upper crossbeam 3.
[0073] The inner mold plate is 8.3m long. The panel is made of 4mm steel plate, the horizontal ribs are made of 70x50x4 rectangular tubes, the side horizontal and vertical ribs are made of 10mm thick steel plate, the stiffening ribs are made of 5mm steel plate, and the frame is equipped with a rotating pin at the chamfer, which can rotate and shrink the inner mold along the pin.
[0074] The inner formwork longitudinal beam 921 supports the inner formwork 92 and serves as a sliding beam during movement. It consists of two H-beams of HN600x200x10x17, each 18.00m long and 3.36m apart at the center. The front end is suspended from the front crossbeam 3, and the rear end is suspended from the top plate of the box girder.
[0075] (9) Tensioning platform The tensioning platform uses ZLP800 electric suspended platform, with two units arranged horizontally.
[0076] (10) Hydraulic control system (travel control) A centralized control system with 30 channels using PLC intelligent synchronous control.
[0077] (11) Monitoring system (optional) Includes visualized monitoring of stress and deformation of key nodes and components; automatic adjustment of elevation of the first two nodes of the main beam; monitoring of construction environment such as wind speed, temperature and humidity; integrated intelligent tensioning and intelligent spray curing; and video monitoring of the entire construction process.
[0078] The bridge-building machine with a zenith crane described in this invention has a strong lifting capacity for the main beam 2, good stability, high construction efficiency, and safe and convenient installation. The zenith crane allows for pre-tying of reinforcing bars at the rear end of the machine before hoisting them into the formwork, significantly improving the efficiency of reinforcing bar tying and construction.
[0079] The anchor plate is made of Q355 steel plate, and both the upper and lower ends are hinged. The tilting of the anchor plate caused by the deviation of the reserved hole position has little impact on its own safety.
[0080] The use of anchored plate rear anchors significantly improves the overturning resistance coefficient. The walking mechanism eliminates the need to replace the rail beams, allowing for a single, continuous travel to the desired position. The system offers safe, reliable, convenient, and fast operation.
[0081] Example 2 A construction method for a bridge-building machine with a zenith crane, using a bridge-building machine with a zenith crane as described in any of Embodiment 1, includes the following steps: S1: Install the bridge-building machine; S2: Conduct a bridge-building machine loading test; S3: Beam segment formwork installation, rebar tying, and prestressed duct installation; After the beam reinforcement is tied as a whole in the previous segment, it is hoisted into the formwork using track beam 4 and hook 10; the bottom plate, web plate and transverse diaphragm are installed, and then the top plate reinforcement is installed. The reinforcement installation is carried out simultaneously with the prestressed duct installation. S4: Pouring concrete; S5: Concrete curing; S6: Prestressed tensioning and duct grouting; S7: Anchoring; S8: The bridge-building machine moves to the next segment; S9: Repeat steps S3-S8 until all symmetrical cantilever grouting sections are completed. S10: Dismantle the bridge-building machine; S11: Construction of the closure section.
[0082] Among them, the specific installation methods for S1: installing the bridge-building machine and S2: conducting the bridge-building machine loading test are as follows: Figures 8-17 As shown.
[0083] A1: Install main beam 2, as follows Figure 8 As shown, it includes the following steps: 1) Remove the formwork of the bridge pier ear wall, and retain the tie rods of the remaining formwork.
[0084] 2) Check whether the reserved holes and embedded parts meet the design requirements; 3) The top surface of the box girder under the pad is leveled with mortar of the same grade; 4) Install the assembly bracket 13; 5) Install the vertical rods 6, horizontal rods, and crossbeams 3 of the assembly platform; 6) Install sleepers, rails, rail extension sections, front supports, and assembly pads; 7) Install main beams B and C on the high mileage side and main beam B on the low mileage side; 8) The main beam on the high mileage side was moved forward by 6.3m; 9) Install the main beam C on the low mileage side; 10) The main beam slipped 2.3m in two directions at the small mileage.
[0085] A2: Install vertical rod 6, diagonal rod 7, track beam 4, and gantry 5, as follows Figure 9 As shown.
[0086] A3: Install the front and rear hangers of the bottom formwork platform, such as Figure 10 As shown, it includes the following steps: 1) Dismantle the assembly frame 13 2) Install the front suspension rod 81 of the bottom formwork platform; 3) Install the bottom formwork platform side rear hanger 82.
[0087] A4: Install the base template, such as Figure 11 As shown, it includes the following steps: 1) Install the crossbeam 3 after installing the bottom formwork platform; 2) Install the front crossbeam 3 of the bottom formwork platform; 3) Install the longitudinal beams of the bottom formwork platform; 4) Install the base template; When the site conditions are suitable for overall hoisting, the bottom formwork platform can also be assembled under the bridge and then hoisted as a whole.
[0088] A5: Install front and rear mounting legs 12, such as Figure 12 As shown, it includes the following steps: 1) Install front mounting legs 11; 2) Install temporary hangers for the outer formwork longitudinal beam on the high mileage side; 3) Install the longitudinal beams of the outer formwork on the high mileage side; 4) Install the longitudinal beams of the outer formwork on the small mileage side, and connect the longitudinal beams of the outer formwork on both sides; 5) Remove the temporary suspension rod on the high mileage side and install it in the reserved hole on the low mileage side; 6) Remove 91 pairs of tie rods from the outer formwork on the high mileage side; 7) Slide the outer formwork 91 on the high mileage side along the longitudinal beam of the outer formwork to the position of section 1; 8) Install the high-mileage side rear hanging leg 12.
[0089] A6: Install the outer mold, such as Figure 13 As shown, it includes the following steps: 1) Install the lower template and frame of the outer mold; 2) Install the rear side hanger; 3) Remove the temporary suspension rods.
[0090] A7: Install the inner formwork longitudinal beam 921, the front hanger 84 of the inner formwork longitudinal beam, and the rear hanger 85 of the inner formwork longitudinal beam, as follows. Figure 14 As shown.
[0091] A8: Conduct a loading test, such as Figure 15 As shown, it includes the following steps: 1) Install the loading test device 14; 2) Conduct a loading test.
[0092] A9: Install inner mold 92, as follows Figure 16 As shown, it includes the following steps: 1) Remove the loading test device 14; 2) Install floor and web reinforcement; 3) Install the inner template.
[0093] A10: Pouring concrete, such as Figure 17 As shown, it includes the following steps: 1) Inspection before concrete pouring; 2) Pour concrete.
[0094] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A bridge builder with a zenith crane, characterized in that, Includes track beams, gantry frames, main beams, crossbeams, hanging legs, bottom formwork platform, suspension system, formwork system, rear anchor, traveling system, tensioning platform, hydraulic control system, electrical system, and safety protection system; Two track beams are spaced apart and connected by a gantry, which is located above the track beams. The track beam is equipped with hooks to form a ceiling-mounted structure. After the previous section of steel reinforcement is tied up, the entire structure can be hoisted into the formwork system using the track beam and hooks. The main beam is located below the track beam, and the two main beams are spaced apart. The track beam and the main beam are connected by diagonal and vertical braces. The crossbeam is bolted to the main beam, and the hanging leg is located below the crossbeam and bolted to the crossbeam. It is used to support the rear support point of the outer formwork longitudinal beam and to suspend the rear hanger of the bottom formwork platform in the traveling state. The bottom formwork platform is used to directly bear the weight of the concrete bottom slab and web of the beam segment, and to provide an operating area for formwork erection and concrete pouring. The suspension system includes front and rear hangers of the bottom formwork platform, front hangers of the outer formwork longitudinal beam, and front and rear hangers of the inner formwork longitudinal beam. The front and rear hangers of the bottom formwork platform are connected to the crossbeam and are used to suspend the bottom formwork platform. The front hangers of the outer formwork longitudinal beam are connected to the crossbeam and are used to suspend the front end of the outer formwork longitudinal beam. The front hangers of the inner formwork longitudinal beam are connected to the crossbeam. The rear hangers of the inner formwork longitudinal beam are connected to the top plate of the box girder. The front and rear hangers of the inner formwork longitudinal beam are used to suspend the inner formwork longitudinal beam. The template system includes an outer template and an inner template. The outer template consists of a web template and a flange template. The outer template longitudinal beams are used to support the outer template. The inner template consists of an inner template, an inner template frame, and an upper crossbeam. The inner template longitudinal beams are used to support the inner template, and the outer template longitudinal beams are used for support and also serve as sliding beams during travel. The rear anchor is used to balance the overturning moment of the main beam while the concrete is being poured.
2. A bridge builder as claimed in claim 1, wherein, The hanging legs include front hanging legs and rear hanging legs that are spaced apart.
3. A bridge-building machine with a zenith crane according to claim 1, characterized in that, In the concrete pouring state, the front end of the bottom formwork platform is suspended from the front crossbeam by the front hanger of the bottom formwork platform, and the rear end is anchored to the bottom plate and flange plate of the completed beam segment by the side rear hanger of the bottom formwork platform. In the traveling state, the rear end of the bottom formwork platform is suspended from the hanging leg by the side rear hanger of the bottom formwork platform.
4. A bridge-building machine with a zenith crane according to claim 1, characterized in that, The bottom formwork platform uses a combination of sling units and rod units for the front and rear suspension rods. The upper lifting section uses screw rods, while the lower fixed section and adjusting section use steel plate slings.
5. A bridge-building machine with a zenith crane according to claim 4, characterized in that, The connections between sling units and between sling units and boom units are made using bolts.
6. A bridge-building machine with a zenith crane according to claim 1, characterized in that, The front end of the outer mold longitudinal beam is suspended on the front cross beam, and the rear end is supported on the hanging leg by a screw.
7. A bridge-building machine with a zenith crane according to claim 1, characterized in that, The rear anchor adopts an anchor plate type rear anchor, and the travel system adopts a walking type.
8. A construction method for a bridge-building machine with a zenith crane, characterized in that, The bridge-building machine with a zenith crane as described in any one of claims 1-7 includes the following steps: S1: Install the bridge-building machine; S2: Conduct a bridge-building machine loading test; S3: Beam segment formwork installation, rebar tying, and prestressed duct installation; After the beam reinforcement is tied as a whole in the previous segment, it is hoisted into the formwork using a track beam and hook; the bottom plate, web plate and transverse diaphragm are installed, and then the top plate reinforcement is installed. The reinforcement installation is carried out simultaneously with the prestressed duct installation. S4: Pouring concrete; S5: Concrete curing; S6: Prestressed tensioning and duct grouting; S7: Anchor sealing.
9. A construction method for a bridge-building machine with a zenith crane according to claim 8, characterized in that, Also includes: S8: The bridge-building machine moves to the next segment; S9: Repeat steps S3-S8 until all symmetrical cantilever grouting sections are completed.
10. A construction method for a bridge-building machine with a zenith crane according to claim 8, characterized in that, Also includes: S10: Dismantle the bridge-building machine; S11: Construction of the closure section.