Modular concrete chimney and method of construction

Abstract

The application belongs to the field of modular construction, and mainly relates to a modular concrete chimney and a construction method, which comprises the following steps: preparing prefabricated modules according to the size of the chimney; installing a hoisting device and an operation platform outside the chimney foundation, so that the operation platform can translate along the chimney; hoisting the first prefabricated module to the chimney foundation, sealing the connecting joint between the first prefabricated module and the foundation; hoisting the next prefabricated module above the last prefabricated module, adjusting the verticality and the levelness, sealing the grouting cavity between the prefabricated modules, injecting grouting material, and completing the connection between the prefabricated modules; adjusting the inner diameter of the operation platform, and translating the operation platform upwards to the current construction position; and repeating the steps until all the prefabricated modules are installed. The application adopts modular assembly, greatly reduces the construction time, and reduces the operation risk of personnel; the operation platform with an adjustable inner diameter is suitable for different construction scenes and has high flexibility; the joint part between the section and the end is strengthened, and the strength safety is ensured.

Description

Technical Field

[0001] This invention relates to the field of modular construction, and more particularly to a modular concrete chimney and its construction method. Background Technology

[0002] The blast furnace hot blast stove chimney is a core supporting facility of the blast furnace system, mainly used to discharge high-temperature flue gas after combustion. These chimneys are typically tall, variable-diameter concrete structures, wider at the bottom and narrower at the top. Traditional construction often employs cast-in-place hydraulic slipform technology, requiring on-site sequential completion of slipform device erection, rebar tying, concrete pouring, and formwork lifting—a repetitive process with drawbacks such as long construction periods, a large amount of work at height, high safety risks, and significant susceptibility to weather conditions. For example, for an 80m high concrete chimney, traditional slipform construction typically takes 2-3 months, with over 70% of the work involving height, increasing the risk of falls and falling objects, and also leading to quality problems such as uneven wall thickness and verticality deviations.

[0003] In recent years, modular construction has been gradually applied to some concrete structures, but the following technical problems still exist in the modular construction of tall, variable-diameter chimneys: (1) Poor adaptability of hoisting equipment: The weight of a single module is large. Traditional truck cranes or crawler cranes need to be equipped with ultra-large tonnage equipment of 300t or above, which has high rental costs and extremely high requirements for site bearing capacity and flatness, making it difficult to adapt to the existing conditions of industrial plants.

[0004] (2) Insufficient strength of the butt joint: The existing ordinary grouting sleeve has limited ability to transfer vertical loads in tall structures, and its seismic and wind resistance performance is insufficient, posing a structural safety hazard.

[0005] (3) Poor adaptability of the operating platform: The chimney is a variable diameter structure. The existing fixed diameter operating platform cannot adapt to the diameter change and requires an independent lifting system, which results in high equipment cost and poor stability.

[0006] (4) Poor compatibility between the chimney body and the construction process: The existing chimney structure design does not fully consider the special requirements of modular construction and lacks a structural structure that matches the corrugated sleeve, large-diameter steel bars and adjustable operating platform. Summary of the Invention

[0007] To address this, this application proposes a modular concrete chimney and its prefabricated construction method, which solves the problems of long construction period, high hoisting cost, insufficient joint strength and poor adaptability of operating platform in the prior art by pre-preparing concrete modules.

[0008] This invention proposes a modular concrete chimney, which is assembled from multiple prefabricated modules from bottom to top. Each prefabricated module has a corrugated sleeve pre-embedded at its bottom, and ribbed steel bars are inserted into the upper end of the prefabricated module. The ribbed steel bars and the corrugated sleeves are correspondingly arranged. Between adjacent prefabricated modules, the ribbed steel bars of the lower prefabricated module are inserted into the corrugated sleeves of the upper prefabricated module.

[0009] Furthermore, the prefabricated module has grouting ports and grout outlets at the top and bottom, and the grouting ports of adjacent prefabricated modules are combined vertically to form a grouting cavity.

[0010] Furthermore, the chimney is conical, and the prefabricated module is annular; each prefabricated module has a different size, and the top dimension of the lower prefabricated module is equal to the bottom dimension of the upper prefabricated module.

[0011] Furthermore, the length of the corrugated sleeve is greater than or equal to 16 times the diameter of the ribbed steel bar.

[0012] A construction method for a modular concrete chimney includes the following steps: S001. Prepare prefabricated modules according to the chimney dimensions; S002. Lay and install hoisting equipment on the outside of the chimney foundation, assemble the operating platform, connect the hoisting points of the operating platform to the hoisting equipment, and move the operating platform up and down along the chimney body. S003. Hoist the first prefabricated module onto the chimney foundation, adjust its verticality and horizontality, and seal the connection between the first prefabricated module and the foundation. S004. Hoist the next precast module to the top of the previous precast module for docking, and adjust the verticality and horizontality. Seal the docking seam between the precast modules to form a connected grouting cavity. Inject high-strength non-shrink grout into the grouting cavity to complete the connection between the precast modules. S005. Adjust the inner diameter of the operating platform according to the current diameter of the chimney body, and move the operating platform upward to the current construction surface position; S006. Repeat steps S004 and S005 until all prefabricated modules are installed, completing the chimney construction.

[0013] Further, in step S004, the prefabricated module docking includes: inserting the ribbed steel bars of the lower prefabricated module into the corrugated sleeve of the upper prefabricated module for docking and assembly.

[0014] Further, in step S004, the grouting operation includes: injecting grouting material from the grouting port at the bottom of the grouting chamber, sealing the grouting ports one by one after all the grouting ports have a continuous flow of grouting material without air bubbles, and finally sealing the grouting port and maintaining the pressure for 30 seconds.

[0015] Furthermore, the operating platform includes multiple ring-shaped platform units, each platform unit including a fixed section and a telescopic section. The telescopic section is connected to the fixed section through a gear and rack telescopic mechanism, and the inner diameter of the operating platform is adjusted by adjusting the extension length of the telescopic section.

[0016] Furthermore, the depth to which the ribbed steel bar is inserted into the corrugated sleeve is greater than or equal to 8 times the diameter of the ribbed steel bar.

[0017] Furthermore, the 28-day compressive strength of the grouting material is greater than or equal to 85 MPa, and the concrete strength grade of the precast module is greater than or equal to C35.

[0018] The beneficial effects of this application are as follows: Adaptable to variable diameter construction: The adjustable inner diameter operating platform dynamically adapts to changes in chimney diameter, improving construction convenience and stability; Enhanced joint strength: The inner wall has an annular corrugated sleeve, which, together with large-diameter steel bars and high-strength grout, provides strong bond strength. The tensile strength of the joint can reach the strength grade of the steel bar parent material, meeting the stress requirements of tall structures. Reduced safety risks: Reduced work at height significantly reduces safety risks such as falls from heights and being struck by objects; Shorten the construction cycle: Modular components are prefabricated in the factory, and only hoisting and docking are required on site, which greatly reduces the construction time; Reduced hoisting costs: Large equipment is no longer needed for hoisting, reducing equipment costs and increasing site adaptability; the operating platform does not require an independent lifting system, further reducing costs. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart illustrating a construction method for a modular concrete chimney. Figure 2 This is an installation diagram illustrating a construction method for a modular concrete chimney. Figure 3 This is a structural diagram of the prefabricated modules and operating platform; Figure 4 This is a top view of the prefabricated modules and operating platform. Figure 5 This is a schematic diagram of the internal structure of the prefabricated module; 1. Chimney; 11. Precast module; 12. Corrugated sleeve; 13. Ribbed steel bar; 14. Grouting port; 15. Grouting cavity; 16. Grout outlet; 2. Operating platform; 21. Platform unit; 22. Fixed section; 23. Expansion section; 3. Lifting device; 4. Chimney foundation. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application. All other implementations obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application. In the various drawings, the same elements are represented by the same or similar reference numerals, and for clarity, the various parts in the drawings are not drawn to scale.

[0022] See Figure 1-5 As shown, this invention proposes a modular concrete chimney, which is assembled from multiple prefabricated modules 11 from bottom to top. Each prefabricated module 11 has a corrugated sleeve 12 pre-embedded at its bottom, and ribbed steel bars 13 are inserted into the upper end of each module. The ribbed steel bars 13 and the corrugated sleeves 12 are correspondingly arranged. Between adjacent prefabricated modules 11, the ribbed steel bars 13 of the lower module 11 are inserted into the corrugated sleeves 12 of the upper module 11. During construction, a chimney foundation 4 is set at the bottom, and the lowermost prefabricated module 11 is fixedly installed on the chimney foundation 4. Operating platforms 2 are spaced along the height of the chimney's side for workers to pass through and perform maintenance. A connection position for a hoisting device 3 is reserved at the top to facilitate module hoisting operations during construction.

[0023] See Figure 3 , 5 As shown, specifically, the chimney 1 is conical, and the prefabricated module 11 is annular; each prefabricated module 11 has a different size, with the top dimension of the lower prefabricated module 11 equal to the bottom dimension of the upper prefabricated module 11. The corrugated sleeves 12 and the ribbed steel bars 13 are evenly spaced along the circumference of the prefabricated module 11, and the number of corrugated sleeves embedded in each prefabricated module 11 is the same as the number of ribbed steel bars, ensuring uniform stress during splicing. Specifically, the length of the corrugated sleeve 12 is greater than or equal to 16 times the diameter 13 of the ribbed steel bar. Each prefabricated module 11 has a body and a method, with the ribbed steel bars 13 penetrating the entire interior of the prefabricated module 11.

[0024] See Figure 5As shown, specifically, the prefabricated module has a grouting port 14 and a grout outlet 16 at the top and bottom, and the grouting ports 14 of adjacent prefabricated modules 11 are combined vertically to form a grouting cavity 15.

[0025] See Figure 1 As shown, a construction method for a modular concrete chimney includes the following steps: S001. Prepare prefabricated modules according to the chimney dimensions; S002. Lay and install hoisting equipment on the outside of the chimney foundation, assemble the operating platform, connect the hoisting points of the operating platform to the hoisting equipment, and move the operating platform up and down along the chimney body. S003. Hoist the first prefabricated module onto the chimney foundation, adjust its verticality and horizontality, and seal the connection between the first prefabricated module and the foundation. S004. Hoist the next precast module to the top of the previous precast module for docking, and adjust the verticality and horizontality. Seal the docking seam between the precast modules to form a connected grouting cavity. Inject high-strength non-shrink grout into the grouting cavity to complete the connection between the precast modules. S005. Adjust the inner diameter of the operating platform according to the current diameter of the chimney body, and move the operating platform upward to the current construction surface position; S006. Repeat steps S004 and S005 until all prefabricated modules are installed, completing the chimney construction.

[0026] Specifically, in step S004, the prefabricated module docking includes: inserting the ribbed steel bar 13 of the lower prefabricated module 11 into the corrugated sleeve 12 of the upper prefabricated module 11 for docking and assembly. Specifically, the depth to which the ribbed steel bar 13 is inserted into the corrugated sleeve 12 is greater than or equal to 8 times the diameter of the ribbed steel bar 13.

[0027] Specifically, in step S004, the grouting operation includes: injecting grout material from the grouting port at the bottom of the grouting cavity 14; after all the grout outlets 16 have continuously flowed out grout material without air bubbles, sealing the grout outlets 16 in sequence; and finally sealing the grouting port 16 and maintaining pressure stability for 30 seconds. The grouting cavity 15 surrounds the outer periphery of each of the corrugated sleeves 12. After the grout material is injected, it can simultaneously fill the grouting cavity 15 and the internal gaps of the corrugated sleeves 12, thus achieving the anchoring connection between the ribbed steel bar 13 and the corrugated sleeve 12, and also completely sealing and filling the joint, ensuring the structural strength and waterproof performance of the connection position. Specifically, the 28-day compressive strength of the grout material is greater than or equal to 85 MPa, and the concrete strength grade of the precast module 11 is greater than or equal to C35.

[0028] Specifically, the operating platform 2 includes multiple ring-shaped platform units 21. Each platform unit 21 includes a fixed section 22 and a telescopic section 23. The telescopic section 23 is connected to the fixed section 22 via a gear and rack telescopic mechanism. The inner diameter of the operating platform 2 can be adjusted by adjusting the extension length of the telescopic section 23. During climbing operations, the inner diameter of the operating platform 2 is adjusted in real time according to the changes in the outer diameter of the chimney 1, ensuring that the operating platform 2 always fits against the outer wall of the chimney. This ensures the safety and stability of the construction personnel and adapts to the gradual narrowing of the chimney 1 from bottom to top. It eliminates the need for additional replacement or reconstruction of the operating platform 1, effectively improving construction efficiency and reducing the difficulty of adjustments during high-altitude operations. During construction, construction personnel can stand on the operating platform 1 to complete a series of operations such as hoisting and positioning the prefabricated module 11, grouting, and joint sealing.

[0029] The beneficial effects of this application are as follows: Adaptable to variable diameter construction: The adjustable inner diameter operating platform dynamically adapts to changes in chimney diameter, improving construction convenience and stability; Enhanced joint strength: The inner wall has an annular corrugated sleeve, which, together with large-diameter steel bars and high-strength grout, provides strong bond strength. The tensile strength of the joint can reach the strength grade of the steel bar parent material, meeting the stress requirements of tall structures. Reduced safety risks: Reduced work at height significantly reduces safety risks such as falls from heights and being struck by objects; Shorten the construction cycle: Modular components are prefabricated in the factory, and only hoisting and docking are required on site, which greatly reduces the construction time; Reduced hoisting costs: Large equipment is no longer needed for hoisting, reducing equipment costs and increasing site adaptability; the operating platform does not require an independent lifting system, further reducing costs.

[0030] In the accompanying drawings of this embodiment, the same or similar reference numerals correspond to the same or similar components. In the description of this application, it should be noted that if terms such as "upper," "lower," "left," and "right" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the accompanying drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0031] In this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, without necessarily requiring or implying any actual relationship or order between these entities or operations. Finally, it should be noted that the above embodiments are clearly illustrative of the invention and not intended to limit the implementation. Those skilled in the art will recognize that various variations and modifications can be made based on the above description. It is neither necessary nor possible to exhaustively describe all possible implementations. However, obvious variations and modifications derived therefrom remain within the scope of this invention.

Claims

1. A modular concrete chimney, characterized in that, It is assembled from multiple prefabricated modules from bottom to top. Each prefabricated module has a corrugated sleeve pre-embedded at its bottom. Ribbed steel bars are inserted into the upper end of the prefabricated module. The ribbed steel bars and the corrugated sleeves are correspondingly arranged. Between adjacent prefabricated modules, the ribbed steel bars of the lower prefabricated module are inserted into the corrugated sleeves of the upper prefabricated module.

2. The modular concrete chimney according to claim 1, characterized in that, The prefabricated module has grouting ports and grout outlets at the top and bottom, and the grouting ports of adjacent prefabricated modules are combined vertically to form a grouting cavity.

3. The modular concrete chimney according to claim 2, characterized in that, The chimney is conical, and the prefabricated module is annular; each prefabricated module is of a different size, and the top dimension of the lower prefabricated module is equal to the bottom dimension of the upper prefabricated module.

4. The modular concrete chimney according to claim 1, characterized in that, The length of the corrugated sleeve is greater than or equal to 16 times the diameter of the ribbed steel bar.

5. A construction method for a modular concrete chimney, characterized in that, Includes the following steps: S001. Prepare prefabricated modules according to the chimney dimensions; S002. Lay and install hoisting equipment on the outside of the chimney foundation, assemble the operating platform, connect the hoisting points of the operating platform to the hoisting equipment, and move the operating platform up and down along the chimney body. S003. Hoist the first prefabricated module onto the chimney foundation, adjust its verticality and horizontality, and seal the connection between the first prefabricated module and the foundation. S004. Hoist the next precast module to the top of the previous precast module for docking, and adjust the verticality and horizontality. Seal the docking seam between the precast modules to form a connected grouting cavity. Inject high-strength non-shrink grout into the grouting cavity to complete the connection between the precast modules. S005. Adjust the inner diameter of the operating platform according to the current diameter of the chimney body, and move the operating platform upward to the current construction surface position; S006. Repeat steps S004 and S005 until all prefabricated modules are installed, completing the chimney construction.

6. The construction method for the modular concrete chimney according to claim 5, characterized in that, In step S004, the prefabricated module docking includes: inserting the ribbed steel bars of the lower prefabricated module into the corrugated sleeve of the upper prefabricated module for docking and assembly.

7. The construction method for the modular concrete chimney according to claim 5, characterized in that, In step S004, the grouting operation includes: injecting grouting material from the grouting port at the bottom of the grouting chamber, sealing the grouting ports one by one after all the grouting ports have a continuous flow of grouting material without air bubbles, and finally sealing the grouting port and maintaining the pressure for 30 seconds.

8. The construction method for the modular concrete chimney according to claim 5, characterized in that, The operating platform includes multiple ring-shaped platform units. Each platform unit includes a fixed section and a telescopic section. The telescopic section is connected to the fixed section through a gear and rack telescopic mechanism. The inner diameter of the operating platform can be adjusted by adjusting the extension length of the telescopic section.

9. The construction method of the modular concrete chimney according to claim 5, characterized in that, The depth to which the ribbed steel bar is inserted into the corrugated sleeve is greater than or equal to 8 times the diameter of the ribbed steel bar.

10. The construction method of the modular concrete chimney according to claim 5, characterized in that, The grouting material has a 28-day compressive strength greater than or equal to 85 MPa, and the precast module has a concrete strength grade greater than or equal to C35.

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