Novel bridge anti-collision guardrail lightweight integrated system

Abstract

The utility model belongs to the field of bridge engineering construction, and relates to a novel bridge anti-collision guardrail lightweight integrated system. Comprising an inner steel formwork and an outer steel formwork which are separated, a support trolley system, a formwork connecting system, a formwork fixing system and a formwork auxiliary system. According to the system, the multifunctional support trolley, flexible formwork connection, firm formwork fixing and efficient formwork auxiliary technologies are integrated, and construction efficiency and safety are remarkably improved. In addition, the system is excellent in operation convenience, structural stability, cost effectiveness and construction quality, and therefore the overall construction process and project quality are effectively improved.

Description

Technical Field

[0001] The utility model belongs to the field of bridge engineering construction and relates to a lightweight integrated system for a new type of bridge anti-collision guardrail. Background Art

[0002] In the construction of bridge infrastructure, the anti-collision wall is a key link to ensure road safety. In this field, although traditional construction techniques and hydraulic formwork trolley techniques provide basic solutions for the project, their limitations in terms of operation efficiency, cost management, system integration, and adaptability still need to be overcome.

[0003] Limitations of traditional small machinery: Solely relying on manual labor for the positioning and installation of formwork, it has high labor intensity, high cost, and is limited in terms of efficiency and safety in complex or restrictive construction environments.

[0004] Limitations of traditional mechanical trolleys: Although traditional counterweight mechanical trolleys provide a working platform for high-altitude operations, they rely on other lifting and transportation equipment for the disassembly, installation, and transportation of formwork. Such reliance on equipment not only increases the project cost but also affects the work efficiency to a certain extent.

[0005] Limitations of hydraulic formwork trolleys: Hydraulic formwork trolleys perform excellently in providing stability and safety, but the complexity of their hydraulic systems leads to cumbersome operation procedures, high maintenance and manufacturing costs. In addition, under specific working conditions such as small curve radii, the applicability of hydraulic trolleys is limited, affecting their wide application in diverse construction environments. Summary of the Utility Model

[0006] The purpose of the utility model is to provide a lightweight integrated system for a new type of bridge anti-collision guardrail. It is particularly suitable for achieving fast, safe, and cost-effective installation of anti-collision walls in the construction of highway bridges. This method simplifies the operation process, reduces maintenance and manufacturing costs, and improves the adaptability and integration of the system.

[0007] To achieve the above purpose, the utility model adopts the following technical solutions:

[0008] A new lightweight integrated system for bridge anti-collision guardrails includes two separated inner and outer steel formworks, a support trolley system, a formwork connection system, a formwork fixing system, and a formwork auxiliary system. The support trolley system realizes the flexible loading and stable positioning of the formwork through cantilever rod technology, height adjustment technology, and counterweight module technology. The formwork connection system uses L-shaped steel hangers and pin shafts to achieve the firm connection of the inner and outer formworks, supplemented by a chain block hanging mechanism for easy operation and adjustment. The formwork fixing system includes the design of tie rod holes at the top and bottom and a quick tensioning screw device to ensure the firm installation of the formwork. The formwork auxiliary system involves precision formwork manufacturing technology, mechanical demoulding devices, formwork verticality fine adjustment devices, and grout stopping processes to improve the construction accuracy and effect.

[0009] The support trolley system includes a support trolley. The main body of the support trolley is a modular counterweight sand box, which is connected to a cantilever rod mechanism at the front. The cantilever rod mechanism is a triangular mechanism composed of vertical rods, horizontal rods, inclined rods, and cantilever rods, which are arranged at multiple intervals. Four corners of the bottom of the support trolley are connected to a universal wheel group that can be manually adjusted in height.

[0010] The above support trolley system integrates three key technologies: First, the cantilever rod technology allows for flexible suspension and adjustment of the outer formwork, enhancing stability and operation efficiency; Second, the height adjustment technology realizes precise adjustment of the trolley height through a combination of manual jacks and universal wheels to adapt to changing construction environments; Finally, the counterweight module technology improves the trolley stability through modular counterweight sand boxes while maintaining balance and adaptability.

[0011] The formwork connection system includes a chain block system, a connection disk mechanism, a formwork connection device, and an outer formwork quick tensioner. The chain block system is connected to the front end of the cantilever rod, and the hook at its end is connected to the lifting point at the bottom of the outer steel formwork. The connection disk mechanism includes an L-shaped steel hanger, a connection turntable, and a turntable pin shaft. The L-shaped steel hanger is connected to the position of the top tie rod of the inner steel formwork, and its end is connected to the outer steel formwork through the connection turntable and the turntable pin shaft. One end of the formwork connection device is connected to the support trolley, and the other end is connected to the inner steel formwork. The outer formwork quick tensioner is connected to the splicing joints of each section of the outer steel formwork.

[0012] The turntable pin shaft includes turntable pin shaft one and turntable pin shaft two. The connection turntable is semi-circular. The turntable pin shaft two is connected to the center of the semi-circular connection turntable. According to the different positioning requirements of the outer steel formwork, the turntable pin shaft one is connected to the corresponding holes around the turntable pin shaft two to lock the relative positions of the inner and outer formworks.

[0013] The above-mentioned template connection system integrates three key technologies. The first technology is to use L-shaped steel hangers and pins to achieve a stable connection between the inner and outer templates. At the same time, it is equipped with a chain hoisting mechanism that facilitates the flipping and operation of the template. The outer template is flipped around the axis through the connecting turntable on the L-shaped steel hanger, realizing the rapid disassembly and assembly of the template. The second technology is the combination of bolt connection between the inner template and pin and quick tensioner between the outer template, in which the pin is welded on one side of the flange to ensure the connection depth. The third technology is that the inner template is quickly lifted and translated synchronously with the trolley through the template bracket and the hanger device, which enhances the flexibility and convenience of construction.

[0014] The template fixing system includes a tension screw rod arranged at the bottom of the inner and outer templates, and a groove is provided at the outer steel template side end of the tension screw rod, which cooperates with the card slot at the corresponding position on the outer steel template;

[0015] The above-mentioned template fixing system includes two key technologies. The first is the design of the tie rod holes at the top and bottom of the template, the bottom is equipped with a quick tie screw device, and the outer nut and gasket are integrated to achieve rapid fixation of the template and enhance stability and safety. The second is the triangular support rod technology, which firmly fixes the template to the prefabricated beam through the fixing parts to ensure the stability of the template.

[0016] The template auxiliary system includes a hydraulic device, a template verticality fine-tuning device, an attached vibrator, and a slurry-stopping mechanism. The hydraulic device is provided with a steel bracket embedded hydraulic device on the top of the inner and outer templates, and two are provided for each template segment. The template verticality fine-tuning device includes two inclined screws, one long and one short, connected to the bottom of the inner steel template. The long screw is located above the short screw, and the two together with the inner steel template form a triangular structure; there are multiple attached vibrators, which are installed on the outer steel template. The slurry-stopping mechanism includes an inner mold bottom slurry-stopping mechanism and an outer mold side edge slurry-stopping mechanism. The inner mold bottom slurry-stopping mechanism is located at the bottom of the inner steel template and is composed of a 5# channel steel buckled slurry-stopping strip. The outer mold side edge slurry-stopping mechanism is located at the bottom of the outer steel template and is composed of a panel outward-turned steel buckled slurry-stopping strip.

[0017] The formwork auxiliary system also includes leveling bolts, matching surface finishing tooling and matching concrete collecting tooling. The leveling bolts are connected to the bottom frame of the formwork and are used to adjust the tightness between the bottom of the formwork and the base after the formwork is installed and reinforced; the matching surface finishing tooling is located at the top connection of the inner and outer formworks; the matching concrete collecting tooling is a funnel connected to the top of the inner and outer formworks.

[0018] The beneficial effects of the utility model are:

[0019] 1. Significantly improved construction safety: This utility model significantly enhances construction safety by reducing high-altitude operations and providing a stable formwork support system. For example, with the use of a bracket trolley and an L-shaped steel hanger, construction workers do not have to directly install or adjust the formwork at high altitudes, greatly reducing the risks of falling and other high-altitude operation-related hazards. Additionally, the chain block hanging mechanism and mechanical demoulding technology reduce the physical labor intensity during operation and minimize the accident risks caused by improper operation. In bridge construction projects adopting this system, the accident incidence rate is 40% lower than that of traditional methods.

[0020] 2. Optimized construction efficiency: Through the rapid connection and disassembly mechanism of the inner and outer formworks and the coordinated movement design of the formwork and the bracket trolley, high-efficiency execution of formwork installation and removal procedures is achieved. Bridge construction projects adopting this utility model save approximately 30% of the construction time compared to traditional methods.

[0021] 3. Enhanced operation convenience: This utility model focuses on user-friendliness in design, especially in formwork installation and adjustment. The design of the bracket trolley system makes the formwork easy to handle and position, while the formwork connection system makes the connection between the inner and outer formworks fast and simple. For example, in actual applications, operators can complete the installation and fixation of the formwork in a short time without complex tools or long-term training.

[0022] 4. Enhanced structural stability and construction quality: The formwork design and fixation technology of this system ensure the stability and reliability of the construction structure. The precision manufacturing of the formwork and the efficient connection technology (such as the quick tie rod device and the triangular strut technology) provide additional support and strength, ensuring the firmness and long-term durability of the formwork during construction. In actual project cases, the bridge crash barriers constructed using the quick installation construction method of the bridge crash barrier and its formwork integration system of this utility model show higher linear straightness and qualified rate of steel bar protective layer in quality inspection compared to traditional construction methods.

[0023] 5. Improved cost-effectiveness: The lightness and high turnover efficiency of the formwork system reduce material and labor costs, while also minimizing the additional expenses caused by low construction efficiency, achieving the maximization of economic benefits. Project cases show that this system can save 20% of the costs compared to traditional methods. Description of the Drawings

[0024] Figure 1 It is the front view of the formwork reinforcement state system in the present invention;

[0025] Figure 2 It is the front view of the formwork opening and closing state system in the present invention;

[0026] Figure 3 It is the side view of the formwork system in the present invention;

[0027] Figure 4 It is a top view of the template system in the present invention;

[0028] Figure 5 This is a diagram of the connection between the inner and outer templates in the present invention;

[0029] Figure 6 This is a diagram after the outer mold in the present invention is turned over;

[0030] Figure 7 This is a mold-removal diagram of the mold frame in the present invention;

[0031] Figure 8 This is a diagram of the slurry-stopping structure at the bottom of the template in the present invention;

[0032] Figure 9 This is a structural diagram of the outer mold joint in the present invention;

[0033] Figure 10 This is a top surface finishing tooling diagram of the present invention;

[0034] Figure 11 This is a diagram of the concrete receiving hopper tooling in the present invention.

[0035] In the figure: 1-support trolley; 2-inner steel formwork; 3-outer steel formwork; 4-fallback chain system; 5-universal wheel set; 6-turntable pin; 7-formwork connection device; 8-tensioning screw; 9-hydraulic device; 10-attached vibrator; 011-turntable pin one; 012-turntable pin two; 11-outer mold side edging stop slurry; 12-inner mold bottom stop slurry; 13-outer mold quick tensioner; 14-matching finishing tooling; 15-concrete receiving hopper; 16-verticality fine-tuning device. DETAILED DESCRIPTION

[0036] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments, but the present invention is not limited to the specific embodiments. Example 1

[0037] In a newly built highway bridge project, a 200-meter-long crash barrier needs to be built, and a new type of bridge crash barrier lightweight integrated system of the utility model is applied for construction.

[0038] It includes two separated steel formworks (inner and outer), a support trolley system, a formwork connection system, a formwork fixing system, and a formwork auxiliary system. Each formwork is 4.5 meters long and 1.2 meters high. The main panel uses a 4-mm thick steel plate, the horizontal and vertical back ribs for enhancing structural stability adopt 6-mm thick steel strips, and the flange frame uses an 8-mm thick steel plate. Pull rod holes are provided at the bottom of both the inner and outer sides of the formwork, with a hole spacing of 800 mm. Pull rods are also correspondingly set at the top, and the top pull rod is used for the tensioning operation at the outer top of the wall. The support trolley system realizes the flexible mounting and stable positioning of the formwork through cantilever rod technology, height adjustment technology, and counterweight module technology. The formwork connection system uses L-shaped steel hangers and pin shafts to achieve the firm connection of the inner and outer formworks, supplemented by a chain hoist hanging mechanism for easy operation and adjustment. The formwork fixing system includes the design of pull rod holes at the top and bottom and a quick tensioning screw device to ensure the firm installation of the formwork. The formwork auxiliary system involves precision formwork manufacturing technology, mechanical demoulding devices, formwork perpendicularity fine adjustment devices, and grout stopping processes, thereby improving the construction accuracy and effect.

[0039] The support trolley system includes a support trolley 1 with a size designed as 2400 mm × 1800 mm × 2000 mm, ensuring sufficient working space and stability. The main body of the support trolley 1 is a modular counterweight sand box, and the front is connected to a cantilever rod mechanism. The cantilever rod mechanism is a triangular mechanism composed of vertical rods, horizontal rods, inclined rods, and cantilever rods, with multiple intervals. The lateral spacing of the vertical rods is 900 mm, the longitudinal spacing is 1200 mm, and the bottom layer step distance is 1500 mm. The four corners of the bottom of the support trolley 1 are connected to a universal wheel set 5 that can be manually adjusted in height;

[0040] The formwork connection system includes a chain hoist system 4, a connection disk mechanism, a formwork frame connection device 7, and an outer formwork quick tensioner 13. The chain hoist system 4 is connected to the front end of the cantilever rod, and the hook at its end is connected to the hanging point at the bottom of the outer steel formwork 3. The connection disk mechanism includes an L-shaped steel hanger 013, a connection turntable 014, and a turntable pin shaft 6. The L-shaped steel hanger 013 is connected to the position of the top pull rod of the inner steel formwork 2, and its end is connected to the outer steel formwork 3 through the connection turntable 014 and the turntable pin shaft 6. One end of the formwork frame connection device 7 is connected to the support trolley 1, and the other end is connected to the inner steel formwork 2. The outer formwork quick tensioner 13 is connected to the splicing position of each section of the outer steel formwork 3;

[0041] The turntable pin shaft 6 includes a turntable pin shaft one 011 and a turntable pin shaft two 012. The connection turntable 014 is semi-circular. The turntable pin shaft two 012 is connected to the center of the semi-circular connection turntable 014. According to the different positioning requirements of the outer steel formwork 3, the turntable pin shaft one 011 is connected to the corresponding holes around the turntable pin shaft two 012, thereby locking the relative positions of the inner and outer formworks;

[0042] The formwork fixing system includes a tension rod 8 arranged at the bottom of the inner and outer formworks. A groove is provided at the end of the steel formwork side of the outer side of the tension rod 8, which is matched with the clamping groove at the corresponding position on the outer steel formwork 3;

[0043] The formwork auxiliary system includes a hydraulic device 9, a formwork verticality fine adjustment device 16, an attached vibrator 10, and a slurry stopping mechanism. The hydraulic device 9 is embedded in a steel bracket at the top of the inner and outer formworks, and two are provided for each formwork segment. The formwork verticality fine adjustment device 16 includes a long and a short stay rod connected to the bottom of the inner steel formwork 2. The long rod is located above the short rod, and the two form a triangular structure with the inner steel formwork 2; A plurality of the attached vibrators 10 are installed on the outer steel formwork 3. The slurry stopping mechanism includes an inner formwork bottom slurry stop 12 and an outer formwork side edge slurry stop 11. The inner formwork bottom slurry stop 12 is located at the bottom of the inner steel formwork 2 and is composed of a No. 5 channel steel pressing a slurry stopping strip. The outer formwork side edge slurry stop 11 is located at the bottom of the outer steel formwork 3 and is composed of a formwork panel turned outwards and a steel section pressing a slurry stopping strip;

[0044] The formwork auxiliary system further includes leveling bolts 17, a supporting finishing tooling 14, and a supporting concrete receiving tooling 15. The leveling bolts 17 are connected to the bottom frame of the formwork and are used to adjust the tightness between the bottom of the formwork and the base after the formwork installation and reinforcement are completed; The supporting finishing tooling 14 is located at the top connection of the inner and outer formworks; The supporting concrete receiving tooling 15 is a funnel connected to the top of the inner and outer formworks. Example 2

[0045] A new type of modular construction method for bridge anti-collision guardrails using the system described in Example 1 specifically includes the following steps:

[0046] S1. Measurement and layout and preparation work: First, conduct a detailed topographic survey and layout to ensure the accuracy of the anti-collision wall axis; Before installing the anti-collision wall formwork, first complete the binding and reinforcement of the anti-collision wall steel bars, and set a slurry stopping rubber strip at the bottom of the anti-collision wall for slurry stopping and leveling;

[0047] S2. Formwork installation: Fix the inner steel formwork 2 to the support trolley 1 through the formwork connection device 7, and hang the outer steel formwork 3 through the chain block system 4 at the cantilever end, so that the outer steel formwork 3 is in a horizontal state when suspended;

[0048] S3. Support trolley adjustment and formwork positioning: Move the support trolley 1 to the construction position, and initially move the support trolley 1 outwards to adjust the horizontal position of the inner steel formwork 2; By adjusting the height of the universal wheel set 5, lift and lower the support trolley 1 to correctly align the bottom of the formwork with the base, then lock the universal wheels, and adjust the bottom support of the trolley bracket to ensure the stability of the trolley;

[0049] S4. Installation of the outer steel formwork: Release the chain block system 4 to turn the outer steel formwork 3 from the horizontal to the vertical state and make it close to the steel bar protection layer limit cushion block. Then, fix and lock the top pin shaft. The outer formwork quick tensioner 13 is used for connecting between the segments of the outer formwork at the splicing joint of the 3 segments of the outer steel formwork, and the operation is convenient and fast.

[0050] S5. Precise adjustment: Conduct measurement review, and use the formwork verticality adjustment device at the bottom of the inner steel formwork 2 to adjust the formwork verticality. Insert the tie bolts 8 at the bottom and tighten and fix them with the formwork on the inner and outer sides. Fasten the inner and outer formworks through the pin shaft on the connecting plate at the top.

[0051] S6. Concrete pouring: Release the chain block system 4 of the support trolley 1 to separate the support trolley 1 from the outer steel formwork 3. Loosen the inner formwork connection device 7 to separate the inner steel formwork 2 from the support trolley 1, and move the support trolley 1 out of the working position. Then, pour the anti-collision wall concrete in layers.

[0052] S7. Preparation for formwork removal: After the concrete pouring is completed, move the support trolley 1 back to its original position, re-hook the chain block system 4 to the outer steel formwork 3, and connect the inner steel formwork 2 to the support trolley 1 again.

[0053] S8. Formwork removal: Loosen and extract the tie bolts 8 at the bottom of the formwork, loosen the pin shaft of the top connecting plate, start the top hydraulic device 9 to make the formwork separate from the concrete surface, turn the outer steel formwork 3 outward around the top rotating shaft to the horizontal position through the chain block system 4, then raise the universal wheel set 5 to lift the support trolley 1 and the formwork as a whole, and move the support trolley 1 together with the formwork as a whole inward to the bridge deck to complete the formwork removal process.

[0054] The above is the preferred embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and the inventive concept of the present invention, makes equivalent substitutions or changes, and shall be covered by the protection scope of the present invention.

Claims

1. A lightweight integrated system for a new type of bridge anti-collision guardrail, characterized in that: It includes two separated inner and outer steel formworks, a support trolley system, a formwork connection system, a formwork fixing system and a formwork auxiliary system; The support trolley system includes a support trolley. The main body of the support trolley is a modular counterweight sand box, and a cantilever rod mechanism is connected to the front part. The cantilever rod mechanism is a triangular mechanism composed of vertical rods, horizontal rods, inclined rods and cantilever rods, which are arranged at multiple intervals. Four corners of the bottom of the support trolley are connected with a universal wheel group that can be manually adjusted in height; The formwork connection system includes a chain block system, a connection disc mechanism, a formwork and support connection device and an outer formwork quick tensioner. The chain block system is connected to the front end of the cantilever rod, and the hook at its end is connected to the lifting point at the bottom of the outer steel formwork. The connection disc mechanism includes an L-shaped steel hanger, a connection turntable and a turntable pin shaft. The L-shaped steel hanger is connected to the position of the top pull rod of the inner steel formwork, and its end is connected to the outer steel formwork through the connection turntable and the turntable pin shaft. One end of the formwork and support connection device is connected to the support trolley, and the other end is connected to the inner steel formwork. The outer formwork quick tensioner is connected to the splicing position of each section of the outer steel formwork; The formwork fixing system includes tension bolts arranged at the bottoms of the inner and outer formworks. A groove is provided at the end of the outer steel formwork side of the tension bolt, which is matched with a corresponding card slot on the outer steel formwork; The formwork auxiliary system includes a hydraulic device, a formwork verticality fine adjustment device, an attached vibrator and a grout stopping mechanism. The hydraulic device is embedded with a hydraulic device in a steel section bracket arranged at the tops of the inner and outer formworks, and two are arranged for each formwork section. The formwork verticality fine adjustment device includes a long and a short stay bar connected to the bottom of the inner steel formwork. The long stay bar is above the short stay bar, and the two form a triangular structure with the inner steel formwork; There are multiple attached vibrators, which are installed on the outer steel formwork. The grout stopping mechanism includes inner formwork bottom grout stopping and outer formwork side edge grout stopping. The inner formwork bottom grout stopping is located at the bottom of the inner steel formwork and is composed of a channel steel pressing a grout stopping strip. The outer formwork side edge grout stopping is located at the bottom of the outer steel formwork and is composed of a panel turning outwards and a channel steel pressing a grout stopping strip.

2. The lightweight integrated system for a new type of bridge anti-collision guardrail according to claim 1, wherein: The turntable pin shaft includes turntable pin shaft 1 and turntable pin shaft 2. The connection turntable is semi-circular. Turntable pin shaft 2 is connected to the center of the semi-circular connection turntable. According to different positioning requirements of the outer steel formwork, turntable pin shaft 1 is connected to the corresponding holes around turntable pin shaft 2, so as to lock the relative positions of the inner and outer formworks.

3. A lightweight integrated system for a new type of bridge anti-collision guardrail according to claim 1, characterized in that: The formwork auxiliary system also includes leveling bolts, a supporting finishing tooling and a supporting concrete receiving tooling. The leveling bolts are connected to the bottom frame of the formwork and are used to adjust the tightness between the bottom of the formwork and the base after the formwork installation and reinforcement are completed; The supporting finishing tooling is located at the top connection of the inner and outer formworks; The supporting concrete receiving tooling is a funnel connected to the tops of the inner and outer formworks.

4. A lightweight integrated system for a new type of bridge anti-collision guardrail according to claim 1, characterized in that: The inner formwork bottom grout stopping is located at the bottom of the inner steel formwork and is composed of a No. 5 channel steel pressing a grout stopping strip.

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