Electric power square culvert disposable pouring forming device and process thereof

Abstract

The application discloses a kind of electric power square culvert disposable pouring forming device and process, and pouring process specific steps are as follows: 1) construction preparation, 2) steel bundle, 3) installation template, erect support, 4) concrete pouring, 5) maintenance form removal;Pouring forming device includes support, steel framework, bottom plate, outer side plate, inner side plate;Support includes first support column, second support column, support disc, cross column;The support disc is equipped with several and is arranged on the second support column, the second support column is inserted into the first support column, and the first support column props the bottom plate, and the cross column is used to connect the second support column and prop the inner side plate;Cross column connects support disc;Steel framework is bundled into square shape.The process and pouring forming device of the application adopt one-time pouring forming process, compared with the traditional twice pouring construction method, greatly compresses construction process, improves construction efficiency and saves investment;Among them, the support can adapt to the construction requirements of square culvert, and the template is installed, adjusted and supported according to the support requirements.

Description

Technical Field

[0001] This invention belongs to the field of building construction technology, and specifically relates to a one-time casting and molding device for power culverts and its process. Background Technology

[0002] Power culverts are constructed using a combination of reinforced steel and concrete. The culvert body consists of one or more square, rectangular, or circular cross sections. During construction, the culvert is divided into several sections according to the settlement joints and constructed in a continuous manner. Each section of the culvert's main structure is divided into three sub-projects: reinforcement, formwork, and concrete. It is a common practice for rectangular cross-section culverts to have their main concrete poured in two stages. A horizontal construction joint is left on the side wall after the two concrete pours, usually located 200mm above the axle of the bottom slab. To prevent water seepage, a waterstop strip and a waterstop steel plate are embedded in the joint.

[0003] This conventional approach can be divided into several construction processes according to the construction sequence: tying the bottom slab and side wall reinforcement to the lap position → installing the bottom slab, side wall formwork below the center line of the waterstop, and waterstop → pouring the bottom slab and side wall concrete below the center line of the waterstop → curing and demolding → tying the upper side wall and top slab reinforcement → installing the side wall and top slab formwork → pouring the side wall and top slab concrete → curing and demolding. The process is tedious and complicated.

[0004] Regarding the support scheme, a search revealed an existing technical announcement number CN221989884U for a high-rise building casting formwork support system. This system utilizes a hollow outer tube, allowing the inner tube to move within it, thus shortening the outer tube's length. It also incorporates insertion holes, clearance holes, and insertion rings to facilitate adjustment of the inner tube's position relative to the outer tube based on the actual building height. Furthermore, it includes connecting pipes, a first convex plate, a second convex plate, connecting rings, multiple connecting holes, and pins to connect the support pipes, forming a stable support system. However, the length of the connecting pipes is fixed and cannot be adjusted adaptively, thus limiting the installation and usage requirements of the outer and inner tubes.

[0005] Further searches revealed a concrete vibrating device with prior art announcement number CN 222101514 U. This solution makes the equipment easy to carry and transport, and the vibrating motor will not stick to the concrete during use, making it easy to transport and use. However, the connecting pipe of the vibrating motor is usually relatively long, and it will still drag the concrete during use, which will increase the load accordingly.

[0006] Based on the aforementioned existing technology, this solution proposes a one-time casting molding device and process for power culverts. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide a one-time casting and forming device and process for power culverts. This process and casting and forming device adopt a one-time casting and forming process, which greatly reduces the construction process, improves construction efficiency and project quality, and saves investment compared with the traditional two-stage casting construction method. The support can adapt to the construction requirements of the culvert and can be installed and adjusted according to the support requirements to support the template.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0009] A device and process for one-time casting of power culverts, the specific steps of which are as follows:

[0010] 1) Construction preparation: Material preparation, including supports, formwork, steel bars, and water-stop bolts; formwork includes base plate, inner side plate, and outer side plate; supports include first column, second column, support plate, and horizontal column.

[0011] 2) Reinforcing bar binding: Bind the reinforcing bars of the skeleton according to the thickness of the top slab, side slab, and bottom slab, and then place them according to the specifications.

[0012] 3) Install templates and erect supports; for power culverts, first tie the steel bars of the bottom slab and side walls, then erect the inner side panels and install the supports, then tie the steel bars of the top slab, and finally install the outer side panels.

[0013] The outer side panels are made of wooden formwork, while the inner side panels and bottom panel are made of plastic-coated wooden formwork. Three-section water-stop tie rods are used inside the side walls of the culvert. The bottom of the support frame is erected by welding the top support frame.

[0014] The inner side panels, outer side panels, and bottom panel are made of ribbed square timber and wooden boards. Before construction, the thickness of the bottom panel, inner side panels, and outer side panels is determined according to the design drawings. A production plan for the inner side panels, outer side panels, and bottom panel is developed according to the drawing requirements, and a layout diagram is drawn. The plan and drawings guide the construction. The inner side panels and outer side panels of the culvert are composed of wooden boards and ribbed square timber, all of which are templates that can be cleaned and dismantled in a timely manner. They are assembled as required and can be reused. The inner side panel support is erected according to the layout dimensions, and the lower chamfer and the square timber ribs of the inner side panel are installed. The inner side panel and the square timber are fixed with steel nails.

[0015] When erecting the support structure, the number of the first and second pillars can be selected according to the size of the culvert. The number of support plates on the second support structure should be appropriately selected and used in conjunction with the connection of the horizontal columns to make the support structure more stable.

[0016] 4) Concrete pouring:

[0017] When vibrating the concrete for the bottom slab of the culvert, try to avoid touching the formwork and tie rods, and also prevent over-vibration and under-vibration. After pouring the bottom slab, pour the concrete for the side walls immediately. The bottom slab should be semi-solidified before pouring the side walls to avoid excessive concrete flow.

[0018] The side wall concrete is poured from the top. During vibration, some concrete will flow into the bottom slab from the bottom opening. Therefore, when vibrating the concrete of the culvert side wall, it is important to control the insertion depth of the vibrator and the vibration time, and allow some of the side wall concrete to flow into the bottom slab to supplement the bottom slab concrete to the design thickness. It is also important to ensure that every part of the side wall is vibrated and compacted.

[0019] Furthermore, the concrete flowing into the base slab is manually removed or leveled, and then vibrated with a plate vibrating motor to ensure that the thickness of the base slab meets the design requirements. When the concrete in the side walls is 0.4-0.65m higher than the concrete in the base slab, the concrete is allowed to complete its initial setting or semi-setting, and the time is carefully controlled so that the concrete in the side walls will basically not flow into the base slab again.

[0020] After the side walls of the culvert are poured, the top slab of the culvert is poured in sequence and vibrated accordingly; an immersion vibrator is used for vibration here.

[0021] The vibratory compaction device includes a back plate, a mounting frame, a vibratory motor, a first through shaft, a second through shaft, a first fixing plate, a control motor, and a battery. The back plate has a pair of support plates with a third sliding groove, and fourth sliding grooves on both sides. A mounting plate at the bottom of the back plate supports the control motor and battery. A carrying strap and a soft pad are provided on one side of the back plate. The mounting frame has fifth sliding grooves on both sides. The first through shaft passes through the mounting frame and is located within the third sliding groove. First limiting plates at both ends of the first through shaft restrict its vertical movement. A pair of second springs are fitted onto the first through shaft and are located on both sides of the mounting frame, pushing the mounting frame and support plates. The second through shaft passes through the fourth and fifth sliding grooves. Second limiting plates at both ends of the second through shaft restrict its horizontal movement. A pair of third springs are fitted onto the second through shaft and are located on both sides of the fifth sliding groove. The vibratory motor is mounted on the mounting frame. A connecting pipe and a vibratory head are sequentially connected to one side of the vibratory motor. A grounding wire at one end of the vibratory motor connects to the ground to protect construction personnel. The vibratory motor is connected to an external power source.

[0022] The first fixed plate is fixedly connected to the support plate and the mounting plate. The first fixed plate is provided with a through groove, a support frame, a steering shaft, and a rotating roller. The connecting pipe enters the gap between the support frame and the first fixed plate, and then winds in a different direction via the steering shaft. A fixed frame is provided in the through groove, and a third limiting plate is provided on one side of the fixed frame. The fixed frame is sleeved onto the connecting pipe. One end of the fixed frame is provided with a pull rope connecting to the rotating roller. The rotating roller is rotatably connected to the first fixed plate. A bevel gear is provided at the end of the rotating roller shaft. A control motor shaft is also provided with a bevel gear that meshes with the bevel gear at the end of the rotating roller shaft. A battery supplies power to the control motor. The control motor provides power to drive the rotating roller to rotate, thereby winding. A pull rope pulls the fixing frame to slide along the through groove, thereby causing the connecting pipe to retract. The support frame is equipped with a second fixing plate, on which a second guide shaft is fixedly connected. The second guide shaft has a sliding third fixing plate and a sleeved tension spring. The third fixing plate is connected to one side of the fixing frame via a pull rope, and the two ends of the tension spring are respectively fixedly connected to the second and third fixing plates. When the connecting pipe needs to be lengthened, the control motor reverses and, in conjunction with the tension spring, pulls the fixing frame along the through groove to one side, thus lengthening the connecting pipe. The first fixing plate is also equipped with a control motor switch and a vibration motor switch for controlling the movement.

[0023] The first fixing plate is equipped with a retaining ring, which is fitted onto the connecting pipe and can scrape off the concrete on the connecting pipe during the tightening process.

[0024] 5) Curing and demolding:

[0025] First, the supports and formwork are dismantled. After the supports are dismantled, the top frame on the bottom plate of the culvert is cut off to keep the surface flat.

[0026] Secondly, concrete curing includes two aspects: humidity and temperature. Curing should begin immediately after the initial setting of concrete. Concrete moisturizing curing is achieved by sprinkling water and covering the concrete. During the curing of concrete in formwork, the concrete should be wrapped in formwork and watered to maintain moisture and prevent it from drying out. The concrete surface should be sprayed with curing water to keep it moist and prevent cracks from forming. Strict control should be exercised to avoid alternating wet and dry conditions on the concrete surface.

[0027] The support structure includes a first column, a second column, a support plate, and a cross column. Several support plates are provided and mounted on the second column. The second column is inserted into the first column, and the first column supports the bottom plate. The cross column connects to the second column and supports the inner side plate. The cross column connects to the support plate. The reinforcing steel frame is bundled into a square shape. Based on the required thickness of the culvert, the support structure supports the bottom plate and inner side plate inside the reinforcing steel frame. The outer side plate and the inner side plate are connected and fixed by several water-stop bolts. A fixed top rod is provided on one side of the outer side plate, with one end of the top rod contacting the soil wall to provide auxiliary support for the outer side plate.

[0028] The first support column is configured as a sleeve, with a first insertion hole on its side wall. A locking mechanism is provided on the first support column to lock the insertion state between the first and second support columns. A top frame is provided at the bottom of the first support column, constructed of reinforcing steel and welded to a steel reinforcement frame to support the first support column. The locking mechanism includes an adjusting plate, a limiting plate, a first insertion shaft, and limiting rings. The adjusting plate is rotatably connected to the first support column. A pair of limiting rings are provided on both sides of the adjusting plate, and the limiting rings are fixedly connected to the first support column to limit and support the adjusting plate. The adjusting plate has an adjusting groove. A pair of limiting plates are respectively and symmetrically fixed to the first support columns on both sides of the adjusting plate. The limiting plate has a first sliding groove. First insertion shafts are provided on both sides of the adjusting plate, each with a limiting block and an adjusting shaft. The limiting block is located within the first sliding groove, and the adjusting shaft is located within the adjusting groove. A support block is provided on the limiting block. The support block is located on one side of the limiting plate to support the first insertion shaft. Rotating the adjusting plate and adjusting it controls the first insertion shaft to slide along the first sliding groove, thereby inserting and withdrawing it from the first insertion hole.

[0029] The second support column is provided with several second insertion holes, the spacing of which is the same as the spacing of the first insertion holes. The second support column is inserted into the first support column and locked by inserting the first insertion shaft into the first insertion hole and the second insertion hole. The top of the second support column is provided with a threaded top column, and one end of the top column is provided with a flange. The flange is provided with several third insertion holes and a sliding connection shaft to the flange. When rotating the top column, the insertion shaft can be pulled out and inserted into the third insertion hole, and the top column can be rotated more easily by pushing the insertion shaft.

[0030] The support plate is provided with several fourth insertion holes and symmetrically arranged second sliding grooves; a top block is provided in the second sliding groove, and a guide shaft that is slidably connected to the support plate is provided at one end of the top block. A spring is provided on the guide shaft, and a pair of second insertion shafts are provided on the top block. The spacing between the second insertion shafts is the same as the spacing between the second insertion holes.

[0031] One side of the support plate is provided with a support ring that is fixedly connected by a connecting column; the support ring is provided with a slot to avoid interfering with the sliding of the top block in the second sliding groove.

[0032] The crossbar includes a crossbar with threaded connecting shafts at both ends, which can be shortened and extended by rotation. One end of the connecting shaft is provided with a threaded top plate and a bracket, which can be disassembled and installed by rotation. The top plate supports the inner side plate, and the bracket is provided with a locking shaft. The bracket is inserted into the support plate and locked in place by inserting the locking shaft into the bracket and the fourth insertion hole.

[0033] The crossbar is provided with a ring, and the ring is provided with a third insertion hole. The crossbar can be rotated more easily by inserting the insertion shaft into the third insertion hole.

[0034] During bracket installation, multiple support plates are installed on the second support column to connect and fix it in conjunction with the cross column, according to the size of the culvert and the support space. The second insertion shaft is disengaged from the insertion state by pulling the guide shaft in the support plate, and the support plate is then slid up and down to adjust the height. The spring pushes the top block to reset the insertion and lock it in place. The first and second support columns are fixed together by a locking mechanism. Rotating the adjustment plate controls the adjustment shaft through the adjustment groove to drive the first insertion shaft to insert into the first and second insertion holes to complete the fixation. Rotating the adjustment plate in the opposite direction controls the first insertion shaft to disengage from the insertion state, and then the height of the second support column is adjusted.

[0035] The advantages of this invention compared to existing technologies are as follows:

[0036] 1) This process and casting device adopt a one-time casting process. Compared with the traditional two-stage casting construction method, the original eight construction processes are compressed into four processes: tying steel bars, installing formwork, pouring concrete, curing and removing formwork, which greatly improves construction efficiency, improves project quality and saves investment.

[0037] Secondly, comparing the two pouring methods of this scheme: From the perspective of the construction process, the one-time pouring reduces the three sub-projects of steel reinforcement, formwork, and concrete from multiple construction processes: tying the bottom slab and side wall reinforcement to the lap position → installing the bottom slab, side wall formwork below the center line of the waterstop, and waterstop → pouring the bottom slab and side wall concrete below the center line of the waterstop → curing and formwork removal → tying the upper side wall and top slab reinforcement → installing the side wall and top slab formwork → pouring the side wall and top slab concrete → curing and formwork removal, to four construction processes. This also reduces one technical interval time, including the time for curing and formwork removal of the bottom slab concrete between the two pouring processes. This facilitates construction organization and management and saves construction time.

[0038] The processing and binding of reinforcing bars for one-time casting reduces the need for rebar joint treatment, reduces workload, and saves steel. The formwork is processed into large panels according to the dimensions of the entire wall, which facilitates installation and dismantling and improves turnover rate. The formwork installation also reduces the treatment of horizontal construction joints, reduces the amount of work, saves waterstops and labor costs, and improves construction efficiency. From the perspective of project quality, the use of large formwork without construction joints in one-time casting of walls improves the appearance quality of the box culvert concrete structure, enhances its anti-seepage and water-permeability capabilities, and strengthens the overall integrity of the structure.

[0039] 2) The first and second pillars of the support structure can be telescopically adjusted to adapt to the support dimensions of the culvert cavity, and the height can be finely adjusted by rotating the top pillar. Furthermore, multiple support plates can be installed on the second pillar according to the requirements of the support structure. These support plates can slide up and down on the second pillar and connect with the cross pillar to make the support structure more stable. Simultaneously, the cross pillars have threaded connecting shafts at both ends, with threaded brackets and top plates on the connecting shafts. The brackets and top plates can be disassembled and replaced according to usage requirements, facilitating connection and support at both ends of the cross pillar. Further, the crossbar has a ring and a third insertion hole; the insertion of the shaft into the third insertion hole assists in rotating the crossbar, making operation more effortless. Finally, the bottom of the support plate has a support ring, which provides secondary support to the support structure, improving its stability.

[0040] 3) When vibrating the side wall during pouring, an immersion vibrator is used. This device can be quickly transferred by carrying it on one's back. It can also achieve vibration reduction effect on the mounting frame and vibrating part through the second and third springs, so that construction personnel can carry it on their backs to avoid strong vibration. Secondly, by controlling the motor in conjunction with the tension spring, the connecting pipe can be extended and retracted, which is convenient for construction personnel to transfer and avoids the connecting pipe dragging the concrete during the transfer, thus increasing the load on the construction personnel. Attached Figure Description

[0041] Appendix Figure 1 This is a schematic diagram of the structure of a one-time casting and molding device for electric culverts according to the present invention. Figure 1 ;

[0042] Appendix Figure 2 This is a schematic diagram of the structure of a one-time casting and molding device for electric culverts according to the present invention. Figure 2 ;

[0043] Appendix Figure 3 This is a schematic diagram of the support structure;

[0044] Appendix Figure 4 This is a structural diagram of the first pillar, the second pillar, and the horizontal pillar;

[0045] Appendix Figure 5 This is a structural diagram of the first pillar;

[0046] Appendix Figure 6 This is a schematic diagram of the support plate structure;

[0047] Appendix Figure 7 This is a schematic diagram of the vibratory compaction device. Figure 1 ;

[0048] Appendix Figure 8 This is a schematic diagram of the vibratory compaction device. Figure 2 ;

[0049] Appendix Figure 9 This is a schematic diagram of the vibratory compaction device. Figure 3 ;

[0050] Appendix Figure 10 This is a schematic diagram of the vibratory compaction device. Figure 4 ;

[0051] Appendix Figure 11 This is a structural diagram of the back panel;

[0052] Appendix Figure 12 This is a structural diagram of the mounting bracket;

[0053] In the diagram: 1. Bracket; 2. First support column; 201. First insertion hole; 21. Locking mechanism; 22. Top frame; 211. Adjusting plate; 2111. Adjusting groove; 212. Limiting plate; 2121. First sliding groove; 213. First insertion shaft; 2131. Limiting block; 2132. Adjusting shaft; 214. Support block; 215. Limiting ring; 3. Second support column; 301. Second insertion hole; 311. Top column; 312. Flange; 313. Third insertion hole; 3 14. Insert shaft; 4. Support plate; 401. Fourth insertion hole; 41. Second slide groove; 42. Top block; 421. Second insertion shaft; 422. Spring; 423. Guide shaft; 43. Support ring; 431. Connecting column; 432. Hollow groove; 5. Horizontal column; 51. Crossbar; 511. Ring; 512. Third insertion hole; 52. Connecting shaft; 53. Top plate; 54. Bracket; 541. Locking shaft; 6. Steel reinforcement frame; 61. Base plate; 7. Outer side plate; 71. Top 72. Water-stop screw rod; 8. Inner side plate; 81. Earth wall; 9. Vibration device; 91. Back plate; 911. Support plate; 912. Third slide groove; 913. Fourth slide groove; 914. Mounting plate; 915. Shoulder strap; 916. Soft pad; 92. Mounting bracket; 921. Fifth slide groove; 93. Vibration motor; 931. Connecting pipe; 932. Vibration head; 933. Grounding wire; 94. First through shaft; 941. First limiting plate; 942. Second spring 95. Second through shaft; 951. Second limiting plate; 952. Third spring; 96. First fixing plate; 9601. Through groove; 961. Support frame; 9611. Second fixing plate; 9612. Tension spring; 9613. Second guide shaft; 962. Steering shaft; 964. Rotating roller; 966. Fixing frame; 9661. Third limiting plate; 9662. Pull rope; 9663. Third fixing plate; 967. Snap ring; 97. Control motor; 98. Battery. Detailed Implementation

[0054] To facilitate understanding by those skilled in the art, the following is in conjunction with the appendix. Figure 1-12 The technical solution of the present invention will be further described in detail below.

[0055] A device and process for one-time casting of power culverts, the specific steps of which are as follows:

[0056] 1) Construction preparation: Material preparation, including supports, formwork, steel bars, and water-stop bolts; formwork includes base plate, inner side plate, and outer side plate; supports include first column, second column, support plate, and horizontal column.

[0057] 2) Reinforcing bar binding: Bind the reinforcing bars of the skeleton according to the thickness of the top slab, side slab, and bottom slab, and then place them according to the specifications.

[0058] 3) Install templates and erect supports; for power culverts, first tie the steel bars of the bottom slab and side walls, then erect the inner side panels and install the supports, then tie the steel bars of the top slab, and finally install the outer side panels.

[0059] The outer side panels are made of wooden formwork, while the inner side panels and bottom panel are made of plastic-coated wooden formwork. Three-section water-stop tie rods are used inside the side walls of the culvert. The bottom of the support frame is erected by welding the top support frame.

[0060] The inner side panels, outer side panels, and bottom panel are made of ribbed square timber and wooden boards. Before construction, the thickness of the bottom panel, inner side panels, and outer side panels is determined according to the design drawings. A production plan for the inner side panels, outer side panels, and bottom panel is developed according to the drawing requirements, and a layout diagram is drawn. The plan and drawings guide the construction. The inner side panels and outer side panels of the culvert are composed of wooden boards and ribbed square timber, all of which are templates that can be cleaned and dismantled in a timely manner. They are assembled as required and can be reused. The inner side panel support is erected according to the layout dimensions, and the lower chamfer and the square timber ribs of the inner side panel are installed. The inner side panel and the square timber are fixed with steel nails.

[0061] When erecting the support structure, the number of the first and second pillars can be selected according to the size of the culvert. The number of support plates on the second support structure should be appropriately selected and used in conjunction with the connection of the horizontal columns to make the support structure more stable.

[0062] 4) Concrete pouring:

[0063] When vibrating the concrete for the bottom slab of the culvert, try to avoid touching the formwork and tie rods, and also prevent over-vibration and under-vibration. After pouring the bottom slab, pour the concrete for the side walls immediately. The bottom slab should be semi-solidified before pouring the side walls to avoid excessive concrete flow.

[0064] The side wall concrete is poured from the top. During vibration, some concrete will flow into the bottom slab from the bottom opening. Therefore, when vibrating the concrete of the culvert side wall, it is important to control the insertion depth of the vibrator and the vibration time, and allow some of the side wall concrete to flow into the bottom slab to supplement the bottom slab concrete to the design thickness. It is also important to ensure that every part of the side wall is vibrated and compacted.

[0065] Furthermore, the concrete flowing into the base slab is manually removed or leveled, and then vibrated with a plate vibrating motor to ensure that the thickness of the base slab meets the design requirements. When the concrete in the side walls is 0.4-0.65m higher than the concrete in the base slab, the concrete is allowed to complete its initial setting or semi-setting, and the time is carefully controlled so that the concrete in the side walls will basically not flow into the base slab again.

[0066] After the side walls of the culvert are poured, the top slab of the culvert is poured in sequence and vibrated accordingly; here, an immersion vibrator 9 is used for vibration.

[0067] The vibrating device 9 includes a back plate 91, a mounting frame 92, a vibrating motor 93, a first through shaft 94, a second through shaft 95, a first fixing plate 96, a control motor 97, and a battery 98. The back plate 91 has a pair of support plates 911, each with a third sliding groove 912. Fourth sliding grooves 913 are located on both sides of the back plate 91. A mounting plate 914 at the bottom of the back plate 91 supports the control motor 97 and the battery 98. A carrying strap 915 and a soft pad 916 are located on one side of the back plate 91. Fifth sliding grooves 921 are located on both sides of the mounting frame 92. The first through shaft 94 passes through the mounting frame 92 and is located within the third sliding groove 912. First limiting plates 941 at both ends of the first through shaft 94 restrict its vertical movement. A pair of second springs 942 are sleeved on the first through shaft 94 and are respectively located on both sides of the mounting frame 92. The second springs 942 push the mounting frame 92 and the support plates 913. Support plate 911; the second through shaft 95 passes through the fourth slide groove 913 and the fifth slide groove 921; the second through shaft 95 is provided with second limiting plates 951 at both ends to restrict the left and right movement of the second through shaft 95; a pair of sleeved third springs 952 are provided on the second through shaft 95, and the third springs 952 are respectively provided on both sides of the fifth slide groove 921; the vibration motor 93 is provided on the mounting frame 92, and a connecting pipe 931 and a vibrating head 932 are connected in sequence on one side of the vibration motor 93. A grounding wire 933 is provided at one end of the vibration motor 93 to connect to the ground to protect the safety of construction personnel. The vibration motor is connected to an external power supply. The vibration motor, together with the connecting pipe and the vibrating head, forms an immersion vibrator. The immersion vibrator is an existing product purchased from the market; a steel wire flexible shaft is provided in the connecting pipe, and the torque is transmitted to the vibrating head through the steel wire flexible shaft. The vibrating head is directly inserted into the concrete to vibrate and do work. This is the working principle and conventional application of the immersion vibrator, which will not be elaborated further.

[0068] The first fixing plate 96 is fixedly connected to the support plate 911 and the mounting plate 914. The first fixing plate 96 is provided with a through groove 9601, a support frame 961, a steering shaft 962, and a rotating roller 964. The connecting pipe 931 enters the gap between the support frame 961 and the first fixing plate 96, and then winds in a different direction through the steering shaft 962. A fixing frame 966 is provided in the through groove 9601. A third limiting plate 9661 is provided on one side of the fixing frame 966. The fixing frame 966 is sleeved on the connecting pipe 931. A pull rope 9662 is provided at one end of the fixing frame 966 to connect to the rotating roller 964. The rotating roller 964 is rotatably connected to the first fixing plate 96. A bevel gear is provided at the shaft end of the rotating roller 964. A bevel gear is provided at the shaft end of the control motor 97 and meshes with the bevel gear at the shaft end of the rotating roller 964. The battery 98 supplies power to the control motor 97. The control motor 97 provides power to drive the rotating roller 964 to rotate, thereby... The winding rope 9662 pulls the fixing frame 966 to slide along the through groove 9601, thereby pulling the connecting tube 931 to retract. The support frame 961 is provided with a second fixing plate 9611, and the second fixing plate 9611 is provided with a fixedly connected second guide shaft 9613. The second guide shaft 9613 is provided with a sliding third fixing plate 9663 and a sleeved tension spring 9612. The third fixing plate 9663 is connected to one side of the fixing frame 966 through the rope 9662, and the two ends of the tension spring 9612 are fixedly connected to the second fixing plate 9611 and the third fixing plate 9663 respectively. When the connecting tube 931 needs to be lengthened, the control motor 97 reverses and, in conjunction with the tension of the tension spring 9612, pulls the fixing frame 966 to slide to one side along the through groove 9601, thereby lengthening the connecting tube 931. The first fixing plate is also provided with a control motor switch and a vibration motor switch for controlling the movement.

[0069] The first fixing plate 96 is provided with a retaining ring 967, which is sleeved on the connecting pipe 931. During the process of tightening the connecting pipe 931, the concrete on the connecting pipe 931 can be scraped off.

[0070] Concrete is centrally mixed at the batching plant, transported to the construction site by concrete mixer trucks, and pumped into the formwork by truck-mounted pumps. Before this, the concrete raw materials can only be used after passing laboratory testing. The culvert is poured symmetrically and synchronously by two pump trucks on the left and right sides, and is formed in one go in the order of first the bottom slab, then the side walls, and finally the top slab. When pouring concrete, it is necessary to pour in layers and vibrate each layer. The thickness of each layer is 20-30cm. The upper layer of concrete should be poured before the lower layer of concrete has initially set or can be reshaped.

[0071] 5) Curing and demolding:

[0072] First, the supports and formwork are dismantled. After the supports are dismantled, the top frame on the bottom plate of the culvert is cut off to keep the surface flat; the exposed part of the water-stop bolt is cut off.

[0073] Secondly, concrete curing includes two aspects: humidity and temperature. Curing should begin immediately after the initial setting of concrete. Concrete moisturizing curing is achieved by sprinkling water and covering the concrete. During the curing of concrete in formwork, the concrete should be wrapped in formwork and watered to maintain moisture and prevent it from drying out. The concrete surface should be sprayed with curing water to keep it moist and prevent cracks from forming. Strict control should be exercised to avoid alternating wet and dry conditions on the concrete surface.

[0074] The support frame 1 includes a first pillar 2, a second pillar 3, a support plate 4, and a horizontal column 5. The support plate 4 is provided with several of these and is located on the second pillar 3. The second pillar 3 is inserted into the first pillar 2, and the first pillar 2 supports the bottom plate 61. The horizontal column 5 is used to connect the second pillar 3 and support the inner side plate 8. The horizontal column 5 is connected to the support plate 4. The steel reinforcement cage 6 is bundled into a square shape. According to the thickness requirements of the culvert, the support frame 1 supports the bottom plate 61 and the inner side plate 8 inside the steel reinforcement cage 6. The outer side plate 7 and the inner side plate 8 are connected and fixed by several water-stop bolts 72. One side of the outer side plate 7 is provided with a fixedly connected top rod 71. One end of the top rod 71 touches the soil wall 81 to achieve auxiliary support for the outer side plate 7. The water-stop bolts are standard parts.

[0075] The first support column 2 is a sleeve, and a first insertion hole 201 is provided on the side wall of the first support column 2. A locking mechanism 21 is provided on the first support column 2 to lock the insertion state between the first support column 2 and the second support column 3. A top frame 22 is provided at the bottom of the first support column 2. The top frame 22 is made of steel bars and welded to the steel frame 6 to support the first support column 2. The locking mechanism 21 includes an adjusting plate 211, a limiting plate 212, a first insertion shaft 213, and a limiting ring 215. The adjusting plate 211 is rotatably connected to the first support column 2. A pair of limiting rings 215 are provided on both sides of the adjusting plate 211. The limiting rings 215 are fixedly connected to the first support column 2 to limit and support the adjusting plate 211. An adjusting groove 2 is provided on the adjusting plate 211. 111; The limiting disk 212 is provided with a pair of first pillars 2 respectively and symmetrically fixed on both sides of the adjusting disk 211; the limiting disk 212 is provided with a first sliding groove 2121; the adjusting disk 211 is provided with a first insertion shaft 213 on both sides, the first insertion shaft 213 is provided with a limiting block 2131 and an adjusting shaft 2132, the limiting block 2131 is provided in the first sliding groove 2121, and the adjusting shaft 2132 is provided in the adjusting groove 2111; the limiting block 2131 is provided with a support block 214; the support block 214 is provided on one side of the limiting disk 212 to support the first insertion shaft 213; by rotating the adjusting disk 211 and adjusting it, the first insertion shaft 213 is controlled to slide along the first sliding groove 2121, thereby inserting and withdrawing from the first insertion hole 201.

[0076] The second support column 3 is provided with a plurality of second insertion holes 301. The spacing of the second insertion holes 301 is the same as the spacing of the first insertion holes 201. The second support column 3 is inserted into the first support column 2 and locked by inserting the first insertion shaft 213 into the first insertion holes 201 and the second insertion holes 301. The top of the second support column 3 is provided with a threaded top column 311. One end of the top column 311 is provided with a flange 312. The flange 312 is provided with a plurality of third insertion holes 313 and a sliding connection shaft 314 to the flange 312. When the top column 311 is rotated, the shaft 314 can be pulled out and inserted into the third insertion hole 313. Pushing the shaft 314 to rotate the top column 311 can be done with less effort.

[0077] The support plate 4 is provided with a plurality of fourth insertion holes 401 and symmetrically arranged second sliding grooves 41; a top block 42 is provided in the second sliding groove 41, and a guide shaft 423 slidably connected to the support plate 4 is provided at one end of the top block 42. A spring 422 is sleeved on the guide shaft 423, and a pair of second insertion shafts 421 are provided on the top block 42. The spacing between the second insertion shafts 421 is the same as the spacing between the second insertion holes 301.

[0078] The support plate 4 is provided with a support ring 43 fixedly connected by a connecting column 431 on one side; the support ring 43 is provided with a slot 432 to avoid interfering with the sliding of the top block 42 in the second slide groove 41.

[0079] The crossbar 5 includes a crossbar 51, with threaded connecting shafts 52 at both ends of the crossbar 51. It can be shortened and extended by rotation. One end of the connecting shaft 52 is provided with a threaded top plate 53 and a bracket 54, which can be disassembled and installed by rotation. The top plate 53 supports the inner side plate 8. The bracket 54 is provided with a locking shaft 541. The bracket 54 is inserted into the support plate 4 and locked in place by inserting the bracket 54 into the fourth insertion hole 401 through the locking shaft 541.

[0080] The crossbar 51 is provided with a ring 511, and the ring 511 is provided with a third insertion hole 512. The crossbar 51 can be rotated more easily by inserting the insertion shaft 314 into the third insertion hole 512.

[0081] During bracket installation, multiple support plates 4 are set on the second support column 3 to connect and fix it with the cross column 5, according to the size of the culvert and the support space. The second insertion shaft 421 is disengaged from the insertion state by pulling the guide shaft 423 in the support plate 4, and then the support plate 4 is slid up and down to adjust the height. The spring 422 pushes the top block 42 to reset the insertion and lock it. The first support column 2 and the second support column 3 are fixed together by the locking mechanism 21. Rotating the adjustment plate 211 controls the adjustment shaft 2132 to drive the first insertion shaft 213 to insert into the first insertion hole 201 and the second insertion hole 301 to complete the fixation through the adjustment groove 2111. Rotating the adjustment plate 211 in the opposite direction can control the first insertion shaft 213 to disengage from the insertion state, and then the height of the second support column 3 can be adjusted.

[0082] In the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention 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, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0083] In the description of this invention, the connection methods are divided into fixed connection and movable connection. Fixed connection methods include, but are not limited to, welding and bolting. Movable connection methods include, but are not limited to, sliding connection, rotating connection, and threaded connection. The connection method to achieve the desired effect should be selected according to the application of the solution. Washers are provided in the connection process of the bolts, fixing bolts, studs and nuts. At the same time, the connection of the bolts, fixing bolts, studs and nuts is fixed by thread locking.

[0084] In summary, the electronic or electrical components, including but not limited to the control motor, battery, and immersion vibrator, are existing components obtained through customization or purchase. The electrical connections between these components, including the control motor and battery, are conventional circuit connections or electrical connections in the prior art and are not within the scope of protection of this invention. Furthermore, according to the design requirements of this design scheme, the power supply should be provided by an external power source.

[0085] In summary, including but not limited to the power systems such as control motors, batteries, and immersion vibrators, as well as the transmission systems output by their respective power systems, protective covers should be provided according to the actual installation location if necessary, and sealing rings should be provided at the relative rotating connections to prevent wear or damage to the power system and transmission system caused by the external environment, and to further ensure the normal operation of the power system and transmission system.

[0086] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A device and process for one-time casting and molding of a power culvert, characterized in that... The specific steps of the casting process are as follows: 1) Construction preparation: Material preparation, including scaffolding, formwork, steel bars, and water-stop bolts; formwork includes base plate, inner side plate, and outer side plate; scaffolding includes first support column, second support column, support plate, and horizontal column; 2) Reinforcing bar binding: Bind the reinforcing bars of the skeleton according to the thickness of the top slab, side slab, and bottom slab, and then place them according to the specifications; 3) Install templates and erect supports; for power culverts, first tie the steel bars of the bottom slab and side walls, then erect the inner side panels and install the supports, then tie the steel bars of the top slab, and finally install the outer side panels. The outer side panels use wooden formwork, while the inner side panels and bottom panel use plastic-coated wooden formwork. Three-section water-stop bolts are used within the culvert sidewalls. The support frame is erected using a welded support structure at the bottom. The inner side panels, outer side panels, and bottom panel are constructed using ribbed square timber and wooden planks. Before construction, based on the thicknesses of the bottom panel, inner side panels, and outer side panels provided in the design drawings, a fabrication plan for the inner side panels, outer side panels, and bottom panel is developed according to the drawing requirements, and a layout diagram is drawn to guide construction. The inner and outer side panels of the culvert are composed of wooden planks and ribbed square timber, all of which are readily removable and reassembled as required. The inner side panel support is erected according to the layout dimensions, and the lower chamfer and inner side panel square timber ribs are installed. The inner side panel is fixed to the square timber with steel nails. When erecting the support frame, the number of the first and second pillars can be selected according to the size of the culvert. The number of support plates on the second support frame should be selected appropriately and used in conjunction with the connection of the horizontal columns to make the support frame more stable. 4) Concrete pouring: When vibrating the concrete for the bottom slab of the culvert, try to avoid touching the formwork and tie rods, and also prevent over-vibration and under-vibration. After pouring the bottom slab, pour the concrete for the side walls immediately. The bottom slab should be semi-solidified before pouring the side walls to avoid excessive concrete flow. The side wall concrete is poured from the top. During vibration, some concrete will flow into the bottom slab from the bottom opening. Therefore, when vibrating the concrete of the culvert side wall, it is important to control the insertion depth of the vibrator and the vibration time, allowing some side wall concrete to flow into the bottom slab to supplement the bottom slab concrete to the design thickness. It is also important to ensure that every part of the side wall is vibrated and compacted. Furthermore, the concrete that has flowed into the bottom slab should be manually removed or leveled, and then vibrated with a flat vibrating motor to make the bottom slab thickness meet the design requirements. When the side wall concrete is 0.4-0.65m higher than the bottom slab concrete, allow the concrete to complete its initial setting or semi-setting, and control the time carefully. At this point, the concrete in the side wall will basically not flow into the bottom slab anymore. After the side walls of the culvert are poured, the top slab of the culvert is poured in sequence and vibrated accordingly; an immersion vibrator is used for vibration here. 5) Curing and demolding: First, the supports and formwork are dismantled. After the supports are dismantled, the top frame on the bottom slab of the culvert is cut off to ensure a smooth surface. Second, concrete curing includes both humidity and temperature. Curing should begin immediately after the concrete has initially set. Water spraying is used for concrete moisturizing curing. During the concrete curing period with the formwork in place, the formwork is wrapped and water is poured to keep the concrete moist and prevent it from drying out. Curing water is sprayed onto the concrete surface to keep it moist and prevent cracks from forming. Strict control is required to avoid alternating wet and dry conditions on the concrete surface.

2. The device and process for one-time casting and molding of power culverts according to claim 1, characterized in that... The support structure includes a first column, a second column, a support plate, and a horizontal column. Several support plates are provided on the second column, which is inserted into the first column. The first column supports the bottom plate. The horizontal column connects to the second column and supports the inner side plate. The horizontal column connects to the support plate. The reinforcing steel frame is bundled into a square shape. According to the required thickness of the culvert, the support structure supports the bottom plate and inner side plate inside the reinforcing steel frame. The outer side plate and the inner side plate are connected and fixed by several water-stop bolts. A fixed top rod is provided on one side of the outer side plate, with one end of the top rod contacting the soil wall to provide auxiliary support for the outer side plate. The first support column is configured as a sleeve, with a first insertion hole on its side wall. A locking mechanism is provided on the first support column to lock the insertion state between the first and second support columns. A top frame is provided at the bottom of the first support column, constructed of reinforcing steel and welded to a steel reinforcement frame to support the first support column. The locking mechanism includes an adjusting plate, a limiting plate, a first insertion shaft, and limiting rings. The adjusting plate is rotatably connected to the first support column. A pair of limiting rings are provided on both sides of the adjusting plate, and the limiting rings are fixedly connected to the first support column to limit and support the adjusting plate. The adjusting plate has an adjusting groove. A pair of limiting plates are respectively and symmetrically fixed to the first support columns on both sides of the adjusting plate. The limiting plate has a first sliding groove. First insertion shafts are provided on both sides of the adjusting plate, each with a limiting block and an adjusting shaft. The limiting block is located within the first sliding groove, and the adjusting shaft is located within the adjusting groove. A support block is provided on the limiting block. The support block is located on one side of the limiting plate to support the first insertion shaft. Rotating the adjusting plate and adjusting it controls the first insertion shaft to slide along the first sliding groove, thereby inserting and withdrawing it from the first insertion hole.

3. The device and process for one-time casting and molding of a power culvert according to claim 1, characterized in that... The second support column is provided with several second insertion holes, the spacing of which is the same as the spacing of the first insertion holes. The second support column is inserted into the first support column and locked by inserting the first insertion shaft into the first insertion hole and the second insertion hole. The top of the second support column is provided with a threaded top column, and one end of the top column is provided with a flange. The flange is provided with several third insertion holes and a sliding connection shaft to the flange. When rotating the top column, the insertion shaft can be pulled out and inserted into the third insertion hole, and the top column can be rotated more easily by pushing the insertion shaft.

4. The device and process for one-time casting and molding of power culverts according to claim 1, characterized in that... The support plate is provided with several fourth insertion holes and symmetrically arranged second sliding grooves; a top block is provided in the second sliding groove, and a guide shaft that is slidably connected to the support plate is provided at one end of the top block. A spring is provided on the guide shaft, and a pair of second insertion shafts are provided on the top block. The spacing between the second insertion shafts is the same as the spacing between the second insertion holes. One side of the support plate is provided with a support ring that is fixedly connected by a connecting column; the support ring is provided with a slot to avoid interfering with the sliding of the top block in the second sliding groove.

5. The device and process for one-time casting and molding of a power culvert according to claim 1, characterized in that... The crossbar includes a crossbar with threaded connecting shafts at both ends, which can be shortened and extended by rotation. One end of the connecting shaft is provided with a threaded top plate and a bracket, which can be disassembled and installed by rotation. The top plate supports the inner side plate, and the bracket is provided with a locking shaft. The bracket is inserted into the support plate and locked in place by inserting the locking shaft into the bracket and the fourth insertion hole.

6. The device and process for one-time casting and molding of power culverts according to claim 5, characterized in that... The crossbar is equipped with a ring, and the ring has a third insertion hole. Inserting the insertion shaft into the third insertion hole helps to rotate the crossbar more easily. During bracket installation, according to the size of the culvert and the support space, multiple support plates are set on the second pillar to connect and fix it with the crossbar. By pulling the guide shaft in the support plate, the second insertion shaft is disengaged from the insertion state, and then the support plate is slid up and down to adjust the height. The spring pushes the top block to reset the insertion and lock it. The first pillar and the second pillar are fixed together by a locking mechanism. Rotating the adjustment plate controls the adjustment shaft through the adjustment groove to drive the first insertion shaft to insert into the first and second insertion holes to complete the fixation. Rotating the adjustment plate in the opposite direction can control the first insertion shaft to disengage from the insertion state, and then the height of the second pillar can be adjusted.

7. The device and process for one-time casting and molding of a power culvert according to claim 1, characterized in that... Step 4) The vibrating device includes a back plate, a mounting frame, a vibrating motor, a first through shaft, a second through shaft, a first fixing plate, a control motor, and a battery. The back plate has a pair of support plates with a third sliding groove, and fourth sliding grooves on both sides. A mounting plate at the bottom of the back plate supports the control motor and battery. A carrying strap and a soft pad are provided on one side of the back plate. The mounting frame has fifth sliding grooves on both sides. The first through shaft passes through the mounting frame and is positioned within the third sliding groove. First limiting plates at both ends of the first through shaft restrict its vertical movement. A sleeve is provided on the first through shaft. The second spring is connected, and a pair of second springs are respectively located on both sides of the mounting frame. The second spring pushes the mounting frame and the support plate. The second through shaft passes through the fourth slide groove and the fifth slide groove. The two ends of the second through shaft are provided with second limiting plates to restrict the left and right movement of the second through shaft. A pair of sleeved third springs are provided on the second through shaft, and the third springs are respectively located on both sides of the fifth slide groove. The vibration motor is located on the mounting frame. One side of the vibration motor is provided with a connecting pipe and a vibrating head connected in sequence. One end of the vibration motor is provided with a grounding wire to connect to the ground to protect the safety of construction personnel. The vibration motor is connected to an external power source.

8. The device and process for one-time casting and molding of a power culvert according to claim 7, characterized in that... The first fixed plate is fixedly connected to the support plate and the mounting plate. The first fixed plate is provided with a through groove, a support frame, a steering shaft, and a rotating roller. The connecting pipe enters the gap between the support frame and the first fixed plate, and then winds in a different direction via the steering shaft. A fixed frame is provided in the through groove, and a third limiting plate is provided on one side of the fixed frame. The fixed frame is sleeved onto the connecting pipe. One end of the fixed frame is provided with a pull rope connecting to the rotating roller. The rotating roller is rotatably connected to the first fixed plate. A bevel gear is provided at the end of the rotating roller shaft. A control motor shaft is also provided with a bevel gear that meshes with the bevel gear at the end of the rotating roller shaft. A battery supplies power to the control motor. The control motor provides power to drive the rotating roller to rotate, thereby winding. A pull rope pulls the fixing frame to slide along the through groove, thereby causing the connecting pipe to retract. The support frame is equipped with a second fixing plate, on which a second guide shaft is fixedly connected. The second guide shaft is equipped with a sliding third fixing plate and a sleeved tension spring. The third fixing plate is connected to one side of the fixing frame via a pull rope, and the two ends of the tension spring are fixedly connected to the second fixing plate and the third fixing plate, respectively. When the connecting pipe needs to be lengthened, the control motor reverses and, in conjunction with the tension of the tension spring, pulls the fixing frame to slide to one side along the through groove, thus lengthening the connecting pipe. The first fixing plate is also equipped with a control motor switch and a vibration motor switch for controlling the movement.

9. The device and process for one-time casting and molding of a power culvert according to claim 7, characterized in that... The first fixing plate is equipped with a retaining ring, which is fitted onto the connecting pipe and can scrape off the concrete on the connecting pipe during the tightening process.

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