Simple template device for special-shaped concrete structure of sedimentation tank structure and construction method

Abstract

The present application relates to the technical field of building construction, in particular to a simple formwork device for irregular concrete structure of sedimentation tank structure and a construction method. The device comprises an outer steel formwork in square shape with an open top, an inflatable core ball formwork arranged inside the cavity of the outer steel formwork, an inflatable and exhaust valve arranged on the top of the inflatable core ball formwork, and anti-skid rubber pads attached to the outer wall of the inflatable core ball formwork in a ring shape. The specific steps are as follows: S1: steel formwork assembly and reinforcement; S2: sealing of the built-in inflatable core formwork; S3: internal reinforcement and pre-burial of the formwork; S4: layered pouring of concrete; S5: curing, demolding and precast component; and S6: on-site assembly and forming construction. The device can stably reproduce regular and smooth curved lines, and improve the flatness of the formed components. The whole set of formwork can uniformly precast standardized irregular components, and compress the construction period.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically a simple formwork device and construction method for an irregularly shaped concrete structure of a sedimentation tank. Background Technology

[0002] Currently, water environment governance projects in China are progressing steadily. Wastewater treatment plants, as core infrastructure for water resource recycling and water pollution control, are seeing their construction scale expand year by year, and the construction standards for supporting structures are constantly improving. High-efficiency micro-sand sedimentation tanks are key treatment units in wastewater treatment plants, equipped with suspended mixing equipment. Below the mixer, an irregularly shaped curved concrete structure needs to be formed, such as... Figure 1 The smoothness and dimensional accuracy of the curved surface directly affect the hydraulic flow and sediment separation effect in the pool, and are key points for construction control of the structure.

[0003] Currently, this type of irregular curved concrete is mostly formed by on-site customization of steel molds and assembly of cut wooden molds, which has many practical shortcomings in construction technology. First, manual cutting and assembly of templates makes it difficult to accurately match the curvature of the surface, resulting in poor surface flatness and uneven surface lines of the formed components, which can easily disrupt the water flow distribution in the pool and reduce the operating efficiency of the sedimentation tank. Second, the process of template customization, on-site support and reinforcement, and dimensional correction is complicated, the overall construction cycle is long, and the on-site labor input is large. Third, special irregular templates can only be adapted to a single specification of curved surface, have poor reusability, and result in large material waste, which increases the overall construction cost. Fourth, the formwork has insufficient resistance to deformation during the concrete pouring stage, which can easily lead to bulging, grout leakage, and formwork displacement, resulting in large deviations in the dimensional of the formed components, requiring a large amount of manpower for repair after forming. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a simple formwork device and construction method for irregularly shaped concrete structures used in sedimentation tanks, which enables convenient construction, cost savings, and shorter construction periods.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] A simple formwork device for an irregularly shaped concrete structure of a sedimentation tank includes a square outer steel formwork with an open top. An inflatable core ball formwork is installed inside the cavity of the outer steel formwork. The outer contour of the inflatable core ball formwork matches the inner curved surface contour of the fan-shaped prefabricated unit of the sedimentation tank. An inflation and deflation valve is provided on the top of the inflatable core ball formwork. An anti-slip rubber pad is attached to the outer wall of the inflatable core ball formwork along the circumferential direction. The anti-slip rubber pad is in close contact and sealed with the inner wall of the outer steel formwork.

[0007] As a preferred embodiment, a further technical solution of the present invention is:

[0008] Preferably, the external steel formwork is made of 10mm thick Q235 cold-rolled steel plate. After sandblasting to remove rust, the surface of the steel plate is coated with epoxy anti-rust and anti-corrosion paint, which can improve the rust resistance of the external steel formwork in the humid construction environment on site and extend the overall service life of the formwork.

[0009] Preferably, the outer wall of the external steel formwork is welded with reinforcing ribs, which can improve the overall structural rigidity of the external steel formwork and alleviate the deformation tendency of the formwork caused by the lateral pressure of concrete pouring.

[0010] Preferably, the reinforcing ribs are made of Q235 steel plates with a thickness of 10mm and a width of 50mm. The reinforcing ribs are evenly arranged along the outer steel formwork with a horizontal spacing of 250mm and a vertical spacing of 200mm, which can evenly distribute the stress on the formwork and further improve the deformation resistance of the outer steel formwork.

[0011] Preferably, the inflatable core spherical template is made of high-strength PVC mesh fabric heat-sealed. The mesh fabric has a tensile strength of ≥1000N / 5cm in both warp and weft directions and a tear resistance of ≥300N. The material itself has good tensile and tear resistance properties, can withstand the lateral pressure generated by concrete pouring, and maintain the stability of the curved surface profile.

[0012] Preferably, the anti-slip rubber pad is 5mm thick and is evenly pasted around the outer wall of the inflatable core spherical template. This can further improve the sealing effect of the template splicing, continuously prevent grout leakage, and at the same time, rely on the friction of the rubber pad to constrain the position of the inflatable core spherical template, reducing the risk of core mold slippage during the pouring process.

[0013] This invention also discloses a construction method for an irregularly shaped concrete structure for a sedimentation tank, the specific steps of which are as follows:

[0014] S1: Steel formwork assembly and reinforcement: Multiple steel plates are spliced ​​together with connecting bolts to form a square open cavity to form an external steel formwork. Reinforcing ribs are welded to the outer wall of the external steel formwork to complete the overall reinforcement.

[0015] S2: Built-in inflatable core mold seal: The inflatable core spherical template is placed into the steel template cavity, and inflated by connecting a high-pressure air pump through the air inflation and exhaust valve, so that the anti-slip rubber pad on the outer wall of the inflatable core spherical template is tightly attached to the inner wall of the steel template, thereby achieving anti-displacement and anti-grout leakage seal;

[0016] S3: Embedded reinforcement inside the template: a steel mesh is laid inside the cavity formed by the inflatable core spherical template and the external steel template. A hoisting hook is embedded in the top of the cavity. The position of the steel mesh is calibrated to ensure that the thickness of the concrete protective layer is not less than 20mm.

[0017] S4: Layered concrete pouring: Concrete is poured into the formwork cavity in layers. The deformation of the steel formwork and the air pressure of the inflatable core spherical formwork are monitored in real time throughout the pouring process. Work is stopped immediately if air leakage or bulging occurs.

[0018] S5: Curing and demolding of precast components: After the concrete has been cured to 75% of its design strength, open the inflation and degassing valve to release the gas inside the inflatable core ball mold, complete the core mold demolding, and use the pre-embedded hook to lift and remove the irregular concrete precast unit.

[0019] S6: On-site assembly and forming construction: Clean the sedimentation tank base and mark the positioning lines and elevation control lines; position the square concrete structure, apply 5~8mm thick M10 bonding mortar to the splicing surface, hoist the irregular concrete precast unit to the installation position, remove the hooks on the joint surface and align and fit it with the square concrete structure; use a level and arc ruler to correct the surface forming accuracy, and seal the splicing gaps with sealant for waterproofing.

[0020] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art:

[0021] This invention employs an external steel formwork combined with an internal inflatable core spherical formwork to form a composite molding system. The inflatable core spherical formwork's contour matches the requirements of irregular curved surfaces, stably replicating smooth, regular curved lines, improving component flatness, and avoiding water flow disturbances. The entire formwork system can prefabricate standardized irregular components, eliminating the tedious on-site cutting and repeated adjustments, simplifying on-site operations, shortening the construction cycle, and reducing on-site labor input. The composite formwork structure is compatible with similar fan-shaped irregular prefabricated units, allowing for repeated reuse, reducing formwork material consumption, and controlling construction costs. The rubber pads on the outer wall of the inflatable core spherical formwork tightly adhere to the inner wall of the external steel formwork to form a sealed structure, limiting core mold displacement during pouring, reducing problems such as mold bulging, grout leakage, and mold running, minimizing component dimensional deviations, and reducing subsequent repair work. Attached Figure Description

[0022] Figure 1 It is a diagram of an irregularly shaped curved concrete structure as defined in the background art;

[0023] Figure 2 This is a top view of the simplified template in an embodiment of the present invention;

[0024] Figure 3 This is a schematic diagram of the main view cross-sectional structure of the simplified template in an embodiment of the present invention;

[0025] Figure 4 This is a schematic diagram of the structure of the irregularly shaped precast concrete unit in an embodiment of the present invention;

[0026] Figure 5 This is a schematic diagram of an irregularly shaped precast concrete unit and a square concrete structure in an embodiment of the present invention;

[0027] Figure 6This is a schematic diagram of the structure after the irregularly shaped precast concrete unit and the square concrete structure are fully bonded together in an embodiment of the present invention.

[0028] Explanation of reference numerals in the attached drawings: 1. External steel formwork; 2. Inflatable core spherical formwork; 3. Inflatable and venting valve; 4. Anti-slip rubber pad; 5. Reinforcing rib; 6. Irregularly shaped precast concrete unit; 7. Hook; 8. Square concrete structure. Detailed Implementation

[0029] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0030] like Figures 2 to 6 As shown in the figure, this embodiment provides a simple template device for an irregular concrete structure of a sedimentation tank, including an external steel template 1 that is square and open at the top. An inflatable core ball template 2 is provided inside the cavity of the external steel template 1. The outer contour of the inflatable core ball template 2 matches the inner curved surface contour of the fan-shaped irregular prefabricated unit 6 of the sedimentation tank. An inflation and deflation valve 3 is provided at the top of the inflatable core ball template 2. An anti-slip rubber pad 4 is attached to the outer wall of the inflatable core ball template 2 along the circumferential direction. The anti-slip rubber pad 4 is fitted and sealed to the inner wall of the external steel template 1.

[0031] The external steel formwork 1 is formed by processing multiple independent steel plates separately. The edges of each steel plate are reserved with corresponding bolt holes. The overall enclosure is completed by connecting bolts. After assembly, the whole forms a regular square open cavity. The internal space dimensions of the cavity match the external dimensions of the fan-shaped prefabricated unit 6. The inflation and deflation valve 3 has a built-in brass sealing valve core and has dual functions of inflation and depressurization. During the inflation stage, a high-pressure air pump can be connected to inject compressed air into the inflatable core spherical formwork 2. During the demolding stage, it can be opened to release the internal gas, maintaining stable internal air pressure during inflation and preventing air leakage and depressurization problems. The anti-slip rubber pad 4 is continuously wrapped around the outer wall of the inflatable core spherical formwork 2. After inflation, the rubber pad 4 is squeezed and adhered to the inner wall of the external steel formwork 1. The friction of the rubber material limits the horizontal displacement of the inflatable core spherical formwork 2 during the pouring process, while filling the gaps in the formwork to block the leakage channels of concrete slurry.

[0032] A construction method for an irregularly shaped concrete structure for a sedimentation tank, the specific steps of which are as follows:

[0033] S1: Steel formwork assembly and reinforcement: Multiple steel plates are spliced ​​together with connecting bolts to form a square open cavity to form the outer steel formwork 1. Reinforcing ribs 5 are welded to the outer wall of the outer steel formwork 1 to complete the overall reinforcement. Before splicing, the splicing end face of each steel plate is leveled, and the bolt holes of each steel plate are aligned before the connecting bolts are inserted and tightened evenly to avoid excessive gaps in some areas. The reinforcing ribs 5 are evenly and fully welded along the outer wall of the steel plate in the horizontal and vertical directions. The welds are continuous and without breaks to improve the overall lateral pressure resistance of the steel plate. After assembly, the squareness of the outer frame is checked with a ruler, and the position of any offset steel plates is corrected.

[0034] S2: Built-in inflatable core mold sealing: Place the inflatable core ball mold 2 into the cavity of the steel mold 1, and inflate it through the inflation and exhaust valve 3 connected to the high-pressure air pump, so that the anti-slip rubber pad 4 on the outer wall of the inflatable core ball mold 2 is tightly attached to the inner wall of the steel mold 1, achieving anti-displacement and anti-grout leakage sealing; before placing the inflatable core ball mold 2, clean the debris on the inner wall of the steel mold 1 to ensure that the inner wall is clean and free of protruding particles; during the inflation operation, slowly increase the pressure and inflate in stages to the standard forming air pressure. After inflation is completed, let it stand and stabilize the pressure for a period of time, and check the adhesion between the anti-slip rubber pad 4 and the inner wall of the steel mold 1. If there is local separation, slightly increase the pressure. Only after confirming that there are no gaps and no air leakage can the next process be carried out.

[0035] S3: Embedded reinforcement inside the formwork: A steel mesh is laid inside the cavity formed by the inflatable core spherical formwork 2 and the outer steel formwork 1. A lifting hook 7 is embedded in the top of the cavity to calibrate the position of the steel mesh and ensure that the concrete cover thickness is not less than 20mm. The steel mesh is integrally formed using thin-diameter hot-rolled steel bars with a uniform mesh distribution. Small pads are placed at the bottom of the mesh for support during placement to accurately control the thickness of the bottom concrete cover. The lifting hook 7 is embedded in the splicing and docking surface of the precast unit 6. The anchoring section of the lifting hook 7 is bent inward and embedded inside the steel mesh, and tied and fixed with the steel mesh to prevent the lifting hook 7 from tilting or shifting during the pouring process. Plain concrete itself has weak crack resistance, and the steel mesh can improve the overall tensile strength of the precast unit 6 and reduce the probability of cracking and damage during demolding and lifting.

[0036] S4: Layered Concrete Pouring: Concrete is poured into the cavity of formwork 1 in layers. The deformation of steel formwork 1 and the air pressure of the inflatable core spherical formwork 2 are monitored in real time throughout the pouring process. If air leakage or bulging occurs, work is stopped immediately. The thickness of each concrete layer is kept uniform. After each layer is poured, the supporting vibration equipment is used to fully vibrate it to eliminate internal air bubbles and ensure the compactness of the molding. A dedicated person is assigned to monitor the formwork system throughout the process and regularly monitor the deformation of the external steel formwork 1 and the air pressure of the inflatable core spherical formwork 2. If any abnormal conditions such as bulging of formwork 1, rapid drop in air pressure, or leakage of grout are found, the pouring operation is stopped immediately. The fault point is reinforced, pressurized, and sealed. Pouring is resumed only after the working conditions are confirmed to be stable. The steel mesh and the pre-embedded hooks 7 are monitored at the same time, and any deviation is promptly reset and adjusted.

[0037] S5: Curing and Demolding Precast Components: After the concrete has cured to 75% of its design strength, open the inflation and degassing valve 3 to release the gas inside the inflatable core spherical mold 2, completing the demolding of the core mold 2. Use the pre-embedded hook 7 to lift and remove the irregularly shaped precast concrete unit 6. After pouring, cover the concrete surface with a moisturizing curing material to maintain a stable temperature and humidity environment. Regularly spray water for curing. Demolding can only be carried out after the concrete strength reaches 75% of the design strength standard. Slowly open the inflation and degassing valve 3 to release the pressure, releasing the internal air in stages to avoid rapid depressurization causing damage to the curved inner wall of the precast unit 6. After the inflatable core spherical mold 2 has fully shrunk, remove it from the top of the cavity. When lifting, the lifting equipment should be smoothly attached to the pre-embedded hook 7, and the precast unit 6 should be slowly lifted to avoid damage to the edges and corners caused by lifting.

[0038] S6: On-site assembly and forming construction: Clean the sedimentation tank base and mark the positioning lines and elevation control lines; position the square concrete structure 8, apply 5-8mm thick M10 bonding mortar to the splicing surface, hoist the irregularly shaped precast concrete unit 6 to the installation position, remove the hooks 7 on the joint surface and align and fit it with the square concrete structure 8; use a level and arc ruler to correct the surface forming accuracy, seal the splicing gaps with sealant for waterproofing, roughen the splicing contact surface of the square concrete structure 8 during the base cleaning stage, remove floating dust and loose aggregate to ensure strong bonding of the bonding mortar; control the coating thickness range when applying the bonding mortar, and evenly coat the splicing surface; after the precast unit 6 is hoisted into place, first use the hooks 7 for initial alignment and support, cut and remove the protruding metal section of the hooks 7 on the splicing surface, remove the protrusion obstruction, and then fully fit and press the precast unit 6 with the square concrete structure 8. After the splicing is completed, control the splicing misalignment difference, use a level to check the overall elevation, and use an arc ruler to verify the precast unit 6. The smoothness of the curved surface is improved, and the deviation position is finely adjusted and corrected. Finally, sealant is filled inside the splicing gap to block the water leakage channel.

[0039] Preferably, the external steel formwork 1 is made of Q235 cold-rolled steel plate with a thickness of 10mm. After the steel plate surface is sandblasted to remove rust, it is coated with epoxy anti-rust and anti-corrosion paint, which can improve the rust resistance of the external steel formwork 1 in the humid construction environment on site and extend the overall service life of the formwork 1.

[0040] Preferably, the outer wall of the external steel formwork 1 is welded with reinforcing ribs 5, which can improve the overall structural rigidity of the external steel formwork 1 and alleviate the deformation tendency of the formwork 1 caused by the lateral pressure of concrete pouring.

[0041] Preferably, the reinforcing ribs 5 are made of Q235 steel plates with a thickness of 10mm and a width of 50mm. The reinforcing ribs 5 are evenly arranged along the outer steel formwork 1 with a horizontal spacing of 250mm and a vertical spacing of 200mm, which can evenly distribute the stress on the formwork 1 and further improve the deformation resistance of the outer steel formwork 1.

[0042] Preferably, the inflatable core spherical template 2 is made of high-strength PVC mesh fabric heat-sealed. The mesh fabric has a tensile strength of ≥1000N / 5cm in both warp and weft directions and a tear resistance of ≥300N. The material itself has good tensile and tear resistance properties and can withstand the lateral pressure generated by concrete pouring, maintaining the stability of the curved surface forming contour of the precast unit 6.

[0043] Preferably, the anti-slip rubber pad 4 is 5mm thick and is evenly pasted around the outer wall of the inflatable core ball template 2. This can further improve the sealing effect of the template 1 splicing and continuously prevent grout leakage. At the same time, the friction of the rubber pad 4 constrains the position of the inflatable core ball template 2, reducing the risk of core mold 2 slippage during the pouring process.

[0044] The above description is merely a preferred embodiment of the present invention and does not limit the scope of the present invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A simple formwork device for an irregularly shaped concrete structure of a sedimentation tank, characterized in that: It includes an external steel template that is square and open at the top. Inside the cavity of the external steel template is an inflatable core ball template. The outer contour of the inflatable core ball template matches the inner curved surface contour of the fan-shaped prefabricated unit of the sedimentation tank. An inflation and deflation valve is provided at the top of the inflatable core ball template. Anti-slip rubber pads are attached to the outer wall of the inflatable core ball template along the circumference. The anti-slip rubber pads are in close contact and sealed with the inner wall of the external steel template.

2. The simplified formwork device for irregularly shaped concrete structures of sedimentation tanks according to claim 1, characterized in that: The external steel formwork is made of 10mm thick Q235 cold-rolled steel plate. The surface of the steel plate is sandblasted to remove rust and then coated with epoxy anti-rust and anti-corrosion paint.

3. The simplified formwork device for irregularly shaped concrete structures of sedimentation tanks according to claim 1, characterized in that: The outer wall of the external steel formwork is welded with reinforcing ribs.

4. The simplified formwork device for irregularly shaped concrete structures of sedimentation tanks according to claim 3, characterized in that: The reinforcing ribs are made of Q235 steel plates with a thickness of 10mm and a width of 50mm. The reinforcing ribs are evenly arranged along the outer steel formwork with a horizontal spacing of 250mm and a vertical spacing of 200mm.

5. The simplified formwork device for irregularly shaped concrete structures of sedimentation tanks according to claim 1, characterized in that: The inflatable core spherical template is made of high-strength PVC mesh fabric heat-sealed. The tensile strength of the mesh fabric in both warp and weft directions is ≥1000N / 5cm, and the tear resistance is ≥300N.

6. The simplified formwork device for irregularly shaped concrete structures of sedimentation tanks according to claim 1, characterized in that: The anti-slip rubber pad is 5mm thick and is evenly pasted around the outer wall of the inflatable core spherical template.

7. A construction method for an irregularly shaped concrete structure of a sedimentation tank, characterized in that, The simple formwork device for irregularly shaped concrete structures of sedimentation tanks, as described in any one of claims 1 to 6, is used, and the specific steps are as follows: S1: Steel formwork assembly and reinforcement: Multiple steel plates are spliced ​​together with connecting bolts to form a square open cavity to form an external steel formwork. Reinforcing ribs are welded to the outer wall of the external steel formwork to complete the overall reinforcement. S2: Built-in inflatable core mold seal: The inflatable core spherical template is placed into the steel template cavity, and inflated by connecting a high-pressure air pump through the air inflation and exhaust valve, so that the anti-slip rubber pad on the outer wall of the inflatable core spherical template is tightly attached to the inner wall of the steel template, thereby achieving anti-displacement and anti-grout leakage seal; S3: Embedded reinforcement inside the template: a steel mesh is laid inside the cavity formed by the inflatable core spherical template and the external steel template. A hoisting hook is embedded in the top of the cavity. The position of the steel mesh is calibrated to ensure that the thickness of the concrete protective layer is not less than 20mm. S4: Layered concrete pouring: Concrete is poured into the formwork cavity in layers. The deformation of the steel formwork and the air pressure of the inflatable core spherical formwork are monitored in real time throughout the pouring process. Work is stopped immediately if air leakage or bulging occurs. S5: Curing and demolding of precast components: After the concrete has cured to 75% of its design strength, open the inflation and degassing valve to release the gas inside the inflatable core ball mold, complete the core mold demolding, and use the pre-embedded hook to lift and remove the irregular concrete precast unit. S6: On-site assembly and forming construction: Clean the sedimentation tank base and mark the positioning lines and elevation control lines; position the square concrete structure, apply 5~8mm thick M10 bonding mortar to the splicing surface, hoist the irregular concrete precast unit to the installation position, remove the hooks on the joint surface and align and fit it with the square concrete structure; use a level and arc ruler to correct the surface forming accuracy, and seal the splicing gaps with sealant for waterproofing.

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