Construction method of super-high curved surface cable tower

Abstract

The application discloses a kind of superhigh curved surface cable tower construction methods, first rely on BIM modeling lofting to obtain accurate contour data, interface numerical control engraver processing modeling wood, and the flat part and arc part of formwork are adjusted simply and conveniently, and inner and outer formwork can be flexibly adjusted to adapt to gradual curved surface, and the component forming precision is high;Two sets of inner and outer wood formwork are equipped to circulate, and non-standard tooling is reduced by matching customized rotating hanging seat, and the component reusability is strong, material cost is effectively saved;Formwork structure is fixed using hanging system, and disassembly and transportation are convenient;Construction is loaded with intelligent hydraulic climbing formwork system, sets up guide rail, climbing frame, operation condition trinity anti-falling system, whole process safety monitoring, high-altitude operation is safe and reliable.

Description

Technical Field

[0001] This invention relates to the field of bridge curved cable tower construction technology, and in particular to a construction method for ultra-high curved cable towers. Background Technology

[0002] As bridge engineering develops towards longer spans, more aesthetically pleasing designs, and higher performance, spatial curved towers, with their excellent wind resistance and vibration reduction capabilities, beautiful architectural shapes, and favorable stress characteristics, have been widely used in long-span cable-stayed bridges and suspension bridges. Traditional straight and zigzag bridge towers can no longer meet the comprehensive requirements of modern bridges for structural performance, urban landscape, and integration with regional culture. Hyperboloid, torsional gradient, and multi-curvature irregular-shaped towers are gradually becoming the mainstream design form for large bridges.

[0003] Currently, the construction of curved tower columns mostly adopts customized steel formwork combined with hydraulic climbing formwork, flipping formwork, or segmental prefabrication assembly technology. However, there are still many shortcomings in practical engineering applications: the control of the line shape of complex spatial curved surfaces is difficult, and manual adjustment of the formwork is prone to problems such as uneven line shape and excessive accuracy deviation; the versatility of gradually changing section formwork is poor, with high processing costs and low turnover rate; the positioning accuracy of curved reinforcement is difficult to guarantee, and appearance defects and shrinkage cracks are prone to occur in concrete pouring; construction measurement, line shape monitoring, and formwork control are mostly independent operations, lacking an integrated intelligent control system, resulting in low construction efficiency, high safety risks, and insufficient quality stability. For example, the construction method of thin-walled steel cylindrical hollow tower columns disclosed in patent CN114856287A is difficult to adapt to the control of complex curved surface lines.

[0004] Existing construction technologies are no longer adequate for the high-efficiency and high-precision construction requirements of ultra-high, long-span, and irregularly shaped curved tower columns, thus hindering the further promotion and application of spatial curved bridge tower technology. Therefore, developing a set of curved tower column construction technologies that are linearly controllable, highly efficient, and adaptable has significant engineering value and practical implications. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a construction method for ultra-high curved cable towers, which features precise control of irregularly shaped curved tower columns and simple and efficient construction.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: This application provides a construction method for ultra-high curved cable towers, including the following steps: S1. Based on the construction design drawings, build a BIM three-dimensional model of the tower column of the cable tower, generate the outline of the cable tower based on the BIM model and complete the shape wood drawings, import the drawings into the CNC engraving machine to complete the shape wood carving, and then complete the overall assembly of the shape wood and the template panel components. S2. The entire cable tower is constructed using hydraulic climbing formwork technology, with two sets of inner and outer formwork structures that are used alternately in a cyclical manner. The outer formwork structure uses a shaped wooden formwork structure, while the inner formwork structure uses an adjustable arc formwork structure. S3. The outer mold structure relies on BIM layout data and CNC engraving machine to dynamically process the shaped wood according to the changes in the tower column outline. The outer mold shape is adaptively adjusted by pressing and bonding the panel with the shaped wood. The inner mold structure is adjusted by adjusting the support and the adjuster in conjunction with pressing and bonding the panel with the wooden I-beam to adapt to the changes in the inner outline of the tower column. S4. Temporarily suspend and fix the hydraulic climbing formwork structure on site through a suspension system to meet the needs of formwork structure disassembly, assembly and turnover construction. S5. A rotating bracket adapted to the shape of the cable tower is used as the climbing formwork connection component. The climbing of the frame is completed through an intelligent hydraulic climbing formwork system, and online safety monitoring is implemented throughout the construction process.

[0007] Further or preferred: In the construction method described, the cross-sectional dimensions of each segment of the tower column are differentiated, and the outline data is updated segment by segment through the BIM model. The processing parameters of the CNC engraving machine are updated synchronously to ensure that the shape of each segment of the shaped wood matches the shape of the corresponding tower column segment, thus eliminating the assembly error of the irregular tower column template.

[0008] In the construction method, the outer mold structure relies on fixed shaped wood to achieve rigid contour shaping, adapting to the linear variable diameter contour of the outer side of the tower column; the inner mold structure relies on an adjustable hydraulic adjuster to achieve flexible arc fine adjustment, adapting to the irregular arc variable diameter contour of the inner side of the tower column.

[0009] In the construction method described, the online safety monitoring system is a three-in-one fall protection system that includes guide rail fall protection, climbing frame fall protection, and working condition fall protection. It also features multiple safety control methods such as facial recognition and password locks, 360° panoramic monitoring, synchronous climbing monitoring, and frame stress monitoring.

[0010] The outer mold structure includes an outer mold back rib, an outer mold I-beam, a shaping board, and an outer mold arc panel arranged sequentially from the outside to the inside, which are fitted and assembled into an integral rigid outer mold structure.

[0011] The outer mold back ribs of two adjacent outer mold structures are connected by a connecting rod structure, and the edges of two adjacent molding plates are joined together.

[0012] The inner mold structure includes a straight inner mold structure and an arc-shaped inner mold structure that are connected to each other. The straight inner mold structure includes an inner mold back rib, an inner mold I-beam, and an inner mold straight panel arranged sequentially from the inside to the outside. The arc-shaped inner mold structure includes an adjusting support, a positioning I-beam, and an arc-shaped inner mold panel arranged sequentially from the inside to the outside. Two adjacent adjusting supports are hinged together, and an adjuster for adjusting the relative angle is provided between the two adjusting supports.

[0013] The adjustable support is provided with hinged lugs on both sides, and two adjustable lugs are provided on the back of the adjustable support. A bracket is provided on the outer side of the adjustable support, and the positioning wooden I-beam is set on the bracket to adjust its inner and outer position.

[0014] A tie rod structure is provided between the outer mold structure and the inner mold structure. The tie rod structure includes a tie rod body with threads at both ends. The outer end of the tie rod body is connected to the outer mold back rib of the outer mold structure, and the inner end of the tie rod body is connected to the inner mold back rib of the inner mold structure.

[0015] The rotating bracket is fixed to the outside of the tower column to secure the guide rail of the hydraulic climbing formwork system. The rotating bracket includes a tower column-side rotating support, a frame-side rotating support, a connecting pin, a wall support, and a wall support hanger. The tower column-side rotating support is fitted and fixed to the concrete surface of the tower column. The tower column-side rotating support and the frame-side rotating support are movably connected by the connecting pin. The wall support is fixed to the outside of the frame-side rotating support, and the climbing formwork frame is hung on the wall support hanger. The two sets of supports can rotate freely through the connecting pin to match the change in the inclination angle of the tower column section.

[0016] Compared with the prior art, the present invention has the following advantages: The construction method for this ultra-high curved cable tower is rationally designed. First, it relies on BIM modeling and layout to obtain accurate contour data, then connects with CNC engraving machines to process the shaped wood. The straight and curved parts of the template are easy to adjust, and the inner and outer templates can be flexibly adjusted to adapt to the gradual curved surface, resulting in high component forming accuracy. It is equipped with two sets of inner and outer wooden templates for recycling, and with customized rotating hangers, non-standard tooling is reduced, the components are highly reusable, and material costs are effectively saved. The template structure is fixed by a hanging system, which is convenient for disassembly, assembly and transportation. The construction is equipped with an intelligent hydraulic climbing formwork system, and a three-in-one fall protection system is set up for guide rails, climbing frames and working conditions, with full-process safety monitoring, making high-altitude operations safe and reliable. Attached Figure Description

[0017] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings: Figure 1 This is a schematic diagram of the template structure of the present invention.

[0018] Figure 2 This is a schematic diagram of the internal mold structure of the present invention. Figure 1 .

[0019] Figure 3 and Figure 4 This is a schematic diagram of the internal mold structure of the present invention. Figure 2 .

[0020] Figure 5 for Figure 1 Enlarged schematic diagram of the corner of the inner mold.

[0021] Figure 6 This is a schematic diagram of the internal mold adjustment structure of the present invention.

[0022] Figure 7 This is a schematic diagram of the outer mold structure of the present invention.

[0023] Figure 8 This is a schematic diagram of the rotating bracket structure of the present invention.

[0024] Figure 9 This is a schematic diagram of the climbing formwork structure of the present invention.

[0025] In the picture: 1. Straight inner mold structure; 2. Curved inner mold structure; 101. Inner mold back rib; 102. Inner mold wooden I-beam; 103. Inner mold straight panel; 201. Adjusting support; 202. Adjuster; 203. Positioning wooden I-beam; 204. Inner mold curved panel. 3. Tie rod structure; 4. External mold structure; 401. Outer mold back rib; 402. Outer mold wooden I-beam; 403. Molding board; 404. Outer mold curved panel. 5. Linkage structure; 6. Rotary bracket structure; 601. Tower column side rotary support; 602. Connecting pin; 603. Frame side rotary support; 604. Wall support; 605. Wall bracket. 7. Main beam of the inner cavity anti-fall platform; 8. Lower suspended platform frame; 9. Guide rail; 10. Middle platform frame; 11. Climbing scaffold cylinder; 12. Load-bearing upright; 13. Upper platform frame; 14. Template suspension structure; 15. Upper platform crossbeam. Detailed Implementation

[0026] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and through the description of the examples.

[0027] Although the invention has been shown and described herein with reference to specific embodiments, it is not intended to be limited to the details shown. Rather, various modifications in detail may be made within the equivalent scope and scope of the claims without departing from the invention. In the drawings, the same item numbers refer to the same elements.

[0028] Throughout this disclosure, various terms are used to describe the physical shape or arrangement of features. Many of these terms are used to describe features conforming to a cylindrical or generally cylindrical geometry with the feature as its radius and a central axis perpendicular to that radius. Unless otherwise specified, the terms are given the following meanings: The terms “longitudinal,” “longitudinal,” “axial,” and “axial” refer to a direction, dimension, or orientation parallel to the central axis. The terms “radial” and “radially” refer to a direction, dimension, or orientation perpendicular to the central axis. The terms “inward” and “inner” refer to a direction, dimension, or orientation extending radially toward the central axis. The terms “outward” and “outer” refer to a direction, dimension, or orientation extending radially away from the central axis.

[0029] In this specification, relative terms such as “horizontal,” “vertical,” “upward,” “downward,” “top,” and “bottom,” and their derivatives (e.g., “horizontal,” “downward,” “upward,” etc.) should be interpreted as referring to the direction described or the direction shown in the accompanying drawings. These relative terms are for ease of description and are not generally intended to require a specific direction.

[0030] The current construction of curved tower columns mostly adopts customized steel formwork combined with hydraulic climbing formwork, flipping formwork, or segmental prefabrication and assembly processes. However, there are still many shortcomings in actual engineering applications: it is difficult to control the line shape of complex spatial curved surfaces, and manual adjustment of formwork is prone to problems such as uneven line shape and excessive accuracy deviation; the versatility of gradually changing section formwork is poor, with high processing costs and low turnover rate; the positioning accuracy of curved reinforcement is difficult to guarantee, and appearance defects and shrinkage cracks are prone to occur in concrete pouring; construction measurement, line shape monitoring and formwork control are mostly independent operations, lacking an integrated intelligent control system, resulting in low construction efficiency, high safety risks and insufficient quality stability.

[0031] To address the aforementioned technical issues, such as Figures 1 to 9 As shown, this application provides a construction method for an ultra-high curved cable tower, including the following steps: S1. Based on the construction design drawings, build a BIM three-dimensional model of the tower column of the cable tower, generate the outline of the cable tower based on the BIM model and complete the shape wood drawings, import the drawings into the CNC engraving machine to complete the shape wood carving, and then complete the overall assembly of the shape wood and the template panel components. S2. The entire cable tower is constructed using hydraulic climbing formwork technology, with two sets of inner and outer formwork structures that are used alternately in a cyclical manner. The outer formwork structure uses a shaped wooden formwork structure, while the inner formwork structure uses an adjustable arc formwork structure. S3. The outer mold structure relies on BIM layout data and CNC engraving machine to dynamically process the shaped wood according to the changes in the tower column outline. The outer mold shape is adaptively adjusted by pressing and bonding the panel with the shaped wood. The inner mold structure is adjusted by adjusting the support and the adjuster in conjunction with pressing and bonding the panel with the wooden I-beam to adapt to the changes in the inner outline of the tower column. S4. Temporarily suspend and fix the hydraulic climbing formwork structure on site through a suspension system to meet the needs of formwork structure disassembly, assembly and turnover construction. S5. A rotating bracket adapted to the shape of the cable tower is used as the climbing formwork connection component. The climbing of the frame is completed through an intelligent hydraulic climbing formwork system, and online safety monitoring is implemented throughout the construction process.

[0032] Furthermore, In the construction method, the cross-sectional dimensions of each segment of the tower column are differentiated. The outline data is updated segment by segment through the BIM model, and the processing parameters of the CNC engraving machine are updated synchronously to ensure that the shape of each segment of the shaped wood matches the shape of the corresponding tower column segment, thus eliminating the assembly error of the irregular tower column template.

[0033] The outer mold structure relies on fixed shaped wood to achieve rigid contour shaping, adapting to the linear variable diameter contour of the outer side of the tower column; the inner mold structure relies on an adjustable hydraulic adjuster to achieve flexible curvature fine adjustment, adapting to the irregular arc variable diameter contour of the inner side of the tower column.

[0034] The online safety monitoring system is a three-in-one fall protection system consisting of guide rail fall protection, climbing frame fall protection, and work condition fall protection. It also incorporates multiple safety control methods, including facial recognition and password locks, 360° panoramic monitoring, synchronous climbing monitoring, and frame stress monitoring. Furthermore, a main beam 7 for an internal cavity fall protection platform is installed inside the inner mold structure, forming a reliable fall protection platform.

[0035] The proposed construction method for ultra-high curved cable towers is rationally designed. First, precise contour data is obtained through BIM modeling and layout. Then, CNC engraving machines are used to process the shaped wooden formwork. The straight and curved sections of the formwork are easily adjustable, and the inner and outer formwork can be flexibly adjusted to adapt to gradually changing curved surfaces, resulting in high component forming accuracy. Two sets of inner and outer wooden formwork are used for cyclical turnover, along with customized rotating hangers to reduce non-standard tooling, enhancing component reusability and effectively saving material costs. The formwork structure is fixed using a hanging system, facilitating easy disassembly, assembly, and transportation. The construction utilizes an intelligent hydraulic climbing formwork system, incorporating a three-in-one fall protection system encompassing guide rails, climbing frames, and operational conditions, ensuring safe and reliable high-altitude operations throughout the entire process.

[0036] In some embodiments, such as Figure 1 and Figure 7 As shown, the outer mold structure 4 includes an outer mold back rib 401, an outer mold I-beam 402, a shaping plate 403, and an outer mold arc panel 404 arranged sequentially from the outside to the inside. The outer mold back rib, the outer mold I-beam, the shaping plate, and the outer mold arc panel are sequentially attached and assembled into an integral rigid outer mold structure.

[0037] The lateral pressure generated by concrete pouring is transmitted step by step from the inside out. The curved panel directly contacts the concrete and bears the surface pressure. The shaped panel evenly disperses the local concentrated stress. The wooden I-beams act as secondary keels to bear the panel load and complete the lateral distribution. Finally, the outer formwork back ribs and main keels collect all the lateral pressure and transmit it to the formwork tie system and support system. This avoids overloading of a single formwork component, completely solves the problems of panel bulging and local deformation during the concrete pouring of high tower columns, and effectively controls the accuracy of the outer curved surface of the tower column.

[0038] This invention adds a dedicated shaping board as the curved base layer, accurately matching the design curvature of the tower column in advance. It fixes the curvature of the template foundation from a structural level, avoiding the common problems of curvature rebound and linear deviation after long-term stress on thin-walled curved panels. Furthermore, for some tower columns with gradual curvature and variable cross-section design features, the curvature and verticality of the template can be locally corrected in a small range by adjusting the gap between the wooden I-beam and the back rib, and the fine-tuning point of the shaping board, without the need for overall template disassembly. The template adjustment process is simple and efficient, significantly reducing the time spent on the installation and correction of each section of the tower column template, and accelerating the overall construction cycle.

[0039] Construction of high-tower columns is a high-altitude, high-risk operation. The integral rigid formwork structure has far superior resistance to wind resistance and overturning compared to split formwork. The multi-layered keel frame forms a grid-like rigid support system, resulting in high structural stability of the formwork itself. This reduces the need for additional temporary reinforcement supports and avoids the safety risks caused by loosening or falling off temporary supports at high altitudes.

[0040] Furthermore, the outer mold back ribs of two adjacent outer mold structures are connected by a connecting rod structure 5, and the edges of two adjacent molding plates are joined together, making the structure stable and reliable.

[0041] In some embodiments, such as Figures 1 to 6 As shown, the inner mold structure includes a straight inner mold structure 1 and an arc-shaped inner mold structure 2 connected to each other; the straight inner mold structure includes an inner mold back rib 101, an inner mold I-beam 102 and an inner mold straight panel 103 arranged sequentially from the inside to the outside; the arc-shaped inner mold structure includes an adjusting support 201, a positioning I-beam 203 and an arc-shaped inner mold panel 204 arranged sequentially from the inside to the outside, two adjacent adjusting supports are hinged together, and an adjuster 202 for adjusting the relative angle is provided between the two adjusting supports.

[0042] The design employs a combination of straight and curved inner molds, which can be matched with variable cross-section or rectangular arc tower columns with rounded corners. The straight section is supported by inner mold back ribs, wooden I-beams, and straight panels, which are stressed in layers from the inside out. The force transmission path is clear, the wooden I-beams have excellent bending resistance, and together with the back ribs, they form an overall rigid skeleton. It is not easy to cause bulging or swelling of the mold when pouring concrete, and the flatness and verticality of the straight side wall of the tower column can be controlled.

[0043] The curved section adopts a combination of hinged adjustable supports and angle adjusters. Adjacent supports can rotate freely by hinge, and the included angle can be precisely locked with the adjuster. One set of curved template unit can be adapted to the corners of different radii of arcs by fine-tuning the angle, eliminating the need to open molds separately for each type of arc and greatly reducing the types of templates to be prepared. The hinged nodes release installation stress, and the supports can self-align slightly during hoisting and mold closing, reducing the risk of misalignment at the joints on site. After the adjuster is locked, the overall rigidity is restored, and the dimensions of the arc contour are stable during the pouring stage.

[0044] The tower column's inner mold adopts a combination structure of straight and curved modules. The straight section relies on back ribs and wooden I-beams to form a high-rigidity, straight forming system, ensuring stable sidewall forming quality. The curved section uses hinged adjustable supports with angle adjusters, allowing for flexible adjustment of the arc curvature. One set of curved components can accommodate various corner radii, offering strong versatility. The modular, split design facilitates prefabrication, hoisting, and turnover. The hinged structure provides self-alignment, reduces seam misalignment, and ensures reasonable zoned stress distribution, preventing mold expansion and deformation.

[0045] The adjustable support has hinged lugs on both opposite sides, and two adjustable lugs on the back. A bracket is located on the outer side of the adjustable support, and the adjustable wooden I-beam is mounted on the bracket. Specifically, adjacent adjustable supports are hinged together by two opposite hinged lugs. The adjuster uses a ball-joint linkage, with the end of the ball-joint linkage hinged to the corresponding adjustable lug of the adjustable support, making adjustment easy.

[0046] In some embodiments, a tie rod structure 3 is provided between the outer mold structure and the inner mold structure; the tie rod structure includes a tie rod body with threads at both ends, the outer end of the tie rod body is connected to the outer mold back rib of the outer mold structure, and the inner end of the tie rod body is connected to the inner mold back rib of the inner mold structure.

[0047] The tie rod structure uses threaded tie rods at both ends to connect the inner and outer mold back ribs. During concrete pouring, it forms a stable tension constraint system, effectively offsetting the lateral expansion pressure of the concrete and preventing the inner and outer molds from bulging and deforming. The fixed length of the tie rods precisely limits the distance between the inner and outer molds, stably controlling the thickness of the tower column wall and ensuring uniform cross-sectional dimensions. At the same time, the tie rods transmit and balance the lateral pressure borne by the mold through the inner and outer mold back ribs, dispersing local concentrated loads, improving the overall rigidity of the entire mold set, and after locking, it can limit the horizontal sliding and misalignment of the inner and outer molds, reducing problems such as joint misalignment and grout leakage, and optimizing the appearance quality of the concrete.

[0048] like Figure 9 As shown, the hydraulic climbing formwork achieves overall upward climbing through alternating support of guide rails and frame, and staged driving of hydraulic cylinders. During the climbing process, force transmission, posture constraints, and safety protection all rely on the wall-mounted brackets.

[0049] The hydraulic climbing formwork system can adopt existing solutions; it includes a lower suspended platform frame, guide rails, a middle platform frame, climbing formwork cylinders, load-bearing uprights, an upper platform frame, a formwork suspension structure, and an upper platform crossbeam; this hydraulic climbing formwork system uses the vertical guide rail 9 as the core load-bearing and guiding component, and is anchored to the formed wall with multiple layers of wall-mounted components. The overall vertical force-bearing frame is built by the load-bearing uprights 12, and a three-layer truss-type operating platform is set up vertically in layers: the lower suspended platform frame 8, the middle platform frame 10, and the upper platform frame 13. The three platforms each have their own functions. The middle platform serves as the main working surface for rebar tying and wall pouring. The upper platform is responsible for rebar splicing, equipment maintenance, and formwork support. The bottom suspended platform can simultaneously carry out exterior facade construction such as lower wall repair and bolt sealing. The truss diagonal bracing structure ensures the overall rigidity of the frame and enables multi-process three-dimensional cross-operation. The upper platform frame has an upper platform crossbeam 15 at the top, and a formwork suspension structure 14 is assembled below the crossbeam. The entire set of wall formwork is directly suspended on this structure, which can complete formwork fine-tuning and demolding operations. It bears the lateral pressure of concrete during pouring and moves synchronously with the frame during the climbing stage, eliminating the need for a tower crane to transport the formwork separately.

[0050] The climbing cylinder 11 is the system's climbing power unit, installed between the load-bearing uprights and the guide rails. It is equipped with synchronous hydraulic control and a pressure relief self-locking braking structure. The operation is divided into two modes: pouring and fixing, and hydraulic climbing. During the pouring construction stage, the cylinder retracts and locks, and all the load of the frame and formwork is transferred to the wall through the wall attachments. After the wall is formed and the formwork is demolded, the cylinder uses the fixed guide rails as a lifting support to push the three-layer platform frame and formwork as a whole to climb synchronously along the guide rails to a standard floor height. Throughout the climbing process, the guide rails are continuously constrained by the wall attachments, providing reliable anti-overturning capability. After climbing into position, the upper wall attachments are locked, the cylinder returns to its original position, and the formwork is adjusted to fit the wall, allowing the next floor pouring cycle to begin. The entire system relies on hydraulic self-climbing operation, significantly reducing the occupation of the tower crane, while the fully enclosed multi-layer protective structure significantly improves the safety performance of high-altitude construction.

[0051] Current climbing formwork supports (wall-attached components) mostly use simple welded brackets or steel supports, which have problems such as low load-bearing capacity, insufficient safety redundancy, lack of reliable anti-fall mechanisms, inconvenient disassembly and assembly, and poor versatility, making it difficult to meet the needs of super high-rise, large-tonnage, and highly synchronous construction. As building heights continue to break records, structural forms become increasingly complex, and requirements for construction safety and intelligent levels continue to rise, traditional supports can no longer meet the technical requirements of modern hydraulic climbing formwork, such as high load-bearing capacity, high reliability, fast turnover, and adaptive variable cross-section.

[0052] To address this issue, the present invention employs a rotating bracket structure 6. This rotating bracket is fixed to the outside of the tower column to secure the guide rails of the hydraulic climbing formwork system. The rotating bracket structure includes a tower column-side rotating support 601, a frame-side rotating support 603, a connecting pin 602, a wall support 604, and a wall support bracket 605. The tower column-side rotating support is fitted and fixed to the concrete surface of the tower column. The tower column-side rotating support and the frame-side rotating support are movably connected by a connecting pin. The wall support is fixed to the outside of the frame-side rotating support, and the climbing formwork frame is hung on the wall support bracket. The two sets of supports achieve free rotation via the connecting pin, matching the changes in the tower column's cross-sectional inclination angle.

[0053] This rotating bracket adopts a hinged double-support structure with a tower column-side rotating support and a frame-side rotating support, combined with a connecting pin. It can rotate freely to adapt to changes in the inclination angle of the tower column section, solving the installation problem of traditional fixed wall-mounted components that cannot adapt to tower columns with varying slopes. The tower column-side support is directly attached to and anchored to the concrete tower column surface, with a clear and stable force transmission path. The frame-side support bears the entire set of hydraulic climbing formwork guide rails and frame loads through the wall-mounted support and wall-mounted brackets. The load is transferred in stages, and the structural stress is balanced, which greatly improves the reliability of the guide rail fixation and the overall load-bearing capacity.

[0054] The specific construction method of this invention is as follows: (1) The inner and outer formwork systems are pre-processed in the back-end. The outer formwork system uses BIM 3D layout to export CAD details, draw the model board drawings and refine the drawings, and import the refined drawings into the CNC engraving machine to carve the model board. On-site, the wooden I-beams, model boards and panels are assembled using professional tools to form the designed tower shape. The inner formwork system is assembled in advance according to the design angle, the hinged adjustment supports are assembled and the angle is adjusted, and then the wooden I-beams and panels are installed to form the inner formwork system.

[0055] (2) After the stiffening frame, steel reinforcement binding, and embedded parts of this section of the pylon are in place, and the strength of the previous section of the pylon meets the design requirements, the inner and outer formwork is removed and the pylon is transported to the rear site for modification. The pylon is equipped with a rotating bracket on the concrete embedded parts of the previous section, the angle of the rotating bracket is adjusted (to adapt to changes in the shape of the pylon), and the climbing guide rail is installed. After the rail is in place, all safety measures and preparations before the climbing frame is lifted are completed.

[0056] (3) The climbing operation of the climbing frame shall be carried out by designated personnel. Before climbing, the climbing control platform shall be operated by the manufacturer’s personnel. The four sides of the climbing frame shall be climbed synchronously. Guide rail synchronous monitoring sensors shall be installed at the lifting cylinder of the climbing frame. If the climbing is out of sync and exceeds the limit, the system shall issue an automatic warning and manually correct and adjust until the climbing frame is completed synchronously. After the climbing is completed, the climbing frame protection and fall prevention measures shall be improved in a timely manner.

[0057] (4) After the climbing frame is completed, the pre-modified inner and outer formwork is transported to the site and the formwork is installed using tower crane equipment. The inner and outer formwork is reinforced with tie rods, and the steel back ribs between individual formwork pieces are connected and reinforced with angle steel. After the formwork is inspected and accepted, the tower column concrete is poured.

[0058] (5) Repeated cycle construction: template modification and processing (two sets of templates are configured for inner and outer molds) — installation of rigid frame, reinforcement binding, installation of embedded parts — removal of upper section template of cable tower, installation of rotating hanger, track climbing — climbing frame climbing — template installation, mold closing and reinforcement, concrete pouring.

[0059] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the concept and technical solution of the present invention, or the direct application of the concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A construction method for an ultra-high curved cable tower, characterized in that: The construction method for the ultra-high curved cable tower includes the following steps: S1. Based on the construction design drawings, build a BIM three-dimensional model of the tower column of the cable tower, generate the outline of the cable tower based on the BIM model and complete the shape wood drawings, import the drawings into the CNC engraving machine to complete the shape wood carving, and then complete the overall assembly of the shape wood and the template panel components. S2. The entire cable tower is constructed using hydraulic climbing formwork technology, with two sets of inner and outer formwork structures that are used alternately in a cyclical manner. The outer formwork structure uses a shaped wooden formwork structure, while the inner formwork structure uses an adjustable arc formwork structure. S3. The outer mold structure relies on BIM layout data and CNC engraving machine to dynamically process the shaped wood according to the changes in the tower column outline. The outer mold shape is adaptively adjusted by pressing and bonding the panel with the shaped wood. The inner mold structure is adjusted by adjusting the support and the adjuster in conjunction with pressing and bonding the panel with the wooden I-beam to adapt to the changes in the inner outline of the tower column. S4. Temporarily suspend and fix the hydraulic climbing formwork structure on site through a suspension system to meet the needs of formwork structure disassembly, assembly and turnover construction. S5. A rotating bracket adapted to the shape of the cable tower is used as the climbing formwork connection component. The climbing of the frame is completed through an intelligent hydraulic climbing formwork system, and online safety monitoring is implemented throughout the construction process.

2. The construction method for ultra-high curved cable towers as described in claim 1, characterized in that: In the construction method described, the cross-sectional dimensions of each segment of the tower column are differentiated, and the outline data is updated segment by segment through the BIM model. The processing parameters of the CNC engraving machine are updated synchronously to ensure that the shape of each segment of the shaped wood matches the shape of the corresponding tower column segment, thus eliminating the assembly error of the irregular tower column template.

3. The construction method for ultra-high curved cable towers as described in claim 1, characterized in that: In the construction method, the outer mold structure relies on fixed shaped wood to achieve rigid contour shaping, adapting to the linear variable diameter contour of the outer side of the tower column; the inner mold structure relies on an adjustable hydraulic adjuster to achieve flexible arc fine adjustment, adapting to the irregular arc variable diameter contour of the inner side of the tower column.

4. The construction method for ultra-high curved cable towers as described in claim 1, characterized in that: In the construction method described, the online safety monitoring system is a three-in-one fall protection system that includes guide rail fall protection, climbing frame fall protection, and working condition fall protection. It also features multiple safety control methods such as facial recognition and password locks, 360° panoramic monitoring, synchronous climbing monitoring, and frame stress monitoring.

5. The construction method for ultra-high curved cable towers as described in claim 3, characterized in that: The outer mold structure includes an outer mold back rib, an outer mold I-beam, a shaping board, and an outer mold arc panel arranged sequentially from the outside to the inside, which are fitted and assembled into an integral rigid outer mold structure.

6. The construction method for ultra-high curved cable towers as described in claim 5, characterized in that: The outer mold back ribs of two adjacent outer mold structures are connected by a connecting rod structure, and the edges of two adjacent molding plates are joined together.

7. The construction method for ultra-high curved cable towers as described in claim 3, characterized in that: The inner mold structure includes a straight inner mold structure and an arc-shaped inner mold structure that are connected to each other. The straight inner mold structure includes an inner mold back rib, an inner mold I-beam, and an inner mold straight panel arranged sequentially from the inside to the outside. The arc-shaped inner mold structure includes an adjusting support, a positioning I-beam, and an arc-shaped inner mold panel arranged sequentially from the inside to the outside. Two adjacent adjusting supports are hinged together, and an adjuster for adjusting the relative angle is provided between the two adjusting supports.

8. The construction method for ultra-high curved cable towers as described in claim 7, characterized in that: The adjustable support is provided with hinged lugs on both sides, and two adjustable lugs are provided on the back of the adjustable support. A bracket is provided on the outer side of the adjustable support, and the positioning wooden I-beam is set on the bracket to adjust its inner and outer position.

9. The construction method for ultra-high curved cable towers as described in claim 3, characterized in that: A tie rod structure is provided between the outer mold structure and the inner mold structure. The tie rod structure includes a tie rod body with threads at both ends. The outer end of the tie rod body is connected to the outer mold back rib of the outer mold structure, and the inner end of the tie rod body is connected to the inner mold back rib of the inner mold structure.

10. The construction method for ultra-high curved cable towers as described in claim 1, characterized in that: The rotating bracket is fixed to the outside of the tower column to secure the guide rail of the hydraulic climbing formwork system. The rotating bracket includes a tower column-side rotating support, a frame-side rotating support, a connecting pin, a wall support, and a wall hanger. The tower column-side rotating support is fitted and fixed to the concrete surface of the tower column. The tower column-side rotating support and the frame-side rotating support are movably connected by the connecting pin. The wall support is fixed to the outside of the frame-side rotating support, and the climbing formwork frame is hung on the wall support via the wall hanger. The two sets of supports can rotate freely through the connecting pin to match the change in the inclination angle of the tower column section.

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