UHPC board form-removal-free cast-in-place concrete municipal pipe gallery system

Abstract

The utility model belongs to the field of municipal pipe gallery construction, and particularly relates to a UHPC board form-removal-free cast-in-place concrete municipal pipe gallery system which comprises an outer mold and an inner mold, a steel reinforcement framework is arranged between the outer mold and the inner mold, the outer mold and the inner mold are made of ultra-high performance concrete in a prefabricated mode, and the outer surface of the inner mold is coated with a waterproof coating layer. A back shore is arranged on the top face of the inner mold, a hole is formed in the bottom face of the inner mold, a nut is downwards fixed through the hole, and the nut is downwards in threaded connection with a set screw. By introducing the outer formwork and the inner formwork which are free of formwork removal, the advantages of factory prefabrication and cast-in-place are combined, the on-site wet construction amount and the formwork removal procedure are reduced, the construction period is remarkably shortened, compared with an existing prefabricated assembly structure, splicing seams are reduced, and the leakage problem is reduced through cooperation with a waterproof coating layer which is integrally prefabricated and painted.

Description

Technical Field

[0001] This utility model belongs to the field of municipal utility tunnel construction, and in particular relates to a UHPC panel cast-in-place concrete municipal utility tunnel system that does not require formwork removal. Background Technology

[0002] As an important component of urban infrastructure, municipal utility tunnels are being constructed on an ever-expanding scale. Cast-in-place construction is the traditional method for municipal utility tunnel construction, but due to its long construction cycle, large amount of on-site wet work, and significant impact from weather and groundwater, the extended road excavation time can also affect traffic and residents' lives. Therefore, prefabricated assembly methods are now being adopted for the construction of municipal utility tunnels. Prefabricated assembly reduces the amount of on-site wet work, but it also presents problems such as high difficulty in on-site assembly, numerous joints, susceptibility to leakage, and poor waterproofing performance. Summary of the Invention

[0003] The problem this invention aims to solve is to overcome the shortcomings of the prior art and provide a UHPC panel cast-in-place concrete municipal pipe gallery system that does not require demolding.

[0004] This invention is achieved through the following technical solution:

[0005] A UHPC (Ultra-High Performance Concrete) panel cast-in-place concrete municipal utility tunnel system without formwork removal includes an outer formwork and an inner formwork, with a steel reinforcement skeleton between them. The outer formwork is a U-shaped shell prefabricated from ultra-high performance concrete, and the inner formwork is a rectangular shell prefabricated from ultra-high performance concrete. The four corners of the inner formwork are chamfered, and the outer surface of the inner formwork is coated with a waterproof coating. Several top supports are integrally prefabricated on the top surface of the inner formwork to support the steel reinforcement skeleton. Several holes are provided on the bottom surface of the inner formwork, and nuts are fixed to the bottom of the holes facing downward. The nuts are threaded downward to connect to set screws, which pass downward through the steel reinforcement skeleton and contact the outer formwork.

[0006] Furthermore, it also includes a vibratory compactor, which is placed inside the inner mold. The vibratory compactor includes a chassis and wheels. An electric lifting platform is installed on the upper surface of the chassis. Telescopic mechanisms are installed on the lower surface of the chassis and on both the left and right sides of the upper surface of the electric lifting platform. The ends of the telescopic rods of the telescopic mechanisms are fixed with vibrators.

[0007] Furthermore, the set screw is an internal hexagon set screw, and a support plate is provided on the bottom surface of the set screw.

[0008] Furthermore, the top support is a short cylinder made of ultra-high performance concrete.

[0009] Furthermore, the thickness of both the outer mold and the inner mold is 3cm.

[0010] Furthermore, the vibrator is an attached flat plate vibrator.

[0011] Furthermore, the telescopic mechanism is an electric telescopic rod or a telescopic hydraulic cylinder.

[0012] Compared with the prior art, the beneficial effects of the present invention are:

[0013] 1. This invention introduces non-removable outer and inner molds, combining the advantages of factory prefabrication and on-site casting, reducing on-site wet work and formwork removal procedures, and significantly shortening the construction cycle.

[0014] 2. This invention only prefabricates the outer and inner mold shells and the steel reinforcement skeleton, reducing the weight of the prefabricated components, facilitating transportation and installation, realizing continuous on-site concrete pouring operations, and ensuring the integrity of the pipe gallery structure.

[0015] 3. Compared with existing prefabricated assembly structures, it reduces splicing seams, and with the overall prefabricated waterproof coating layer, it reduces leakage problems.

[0016] 4. The formwork system of this invention does not require the erection of traditional concrete pouring formwork in the early stage, and there is no need to dismantle the formwork in the later stage, which reduces the trench excavation width, improves the construction efficiency, and reduces excavation waste; on the basis of the formwork system of this invention, the on-site pouring reduces the wet work on site and the impact on groundwater, which is in line with the concept of green building.

[0017] 5. The vibratory compactor of this invention enables compaction inside the formwork, improving the efficiency and quality of concrete pouring operations. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure after the inner and outer molds are assembled in this embodiment;

[0019] Figure 2 This is a schematic diagram of the internal mold structure in this embodiment;

[0020] Figure 3 This is a schematic diagram of the cross-sectional structure of the inner mold in this embodiment;

[0021] Figure 4 This is a schematic diagram of the steel frame structure in this embodiment;

[0022] Figure 5 This is a schematic diagram of the vibratory compaction vehicle structure in this embodiment;

[0023] Figure 6 This is a top-view structural diagram of the vibratory compactor in this embodiment;

[0024] Figure 7 This is a partial enlarged structural diagram of the hole in this embodiment;

[0025] Figure 8 This is a schematic diagram of the disassembled structure at the hole in this embodiment.

[0026] In the diagram, 1 is the outer mold, 2 is the inner mold, 3 is the steel reinforcement frame, 4 is the top support, 5 is the hole, 6 is the vibratory compactor, 7 is the chassis, 8 is the wheel, 9 is the electric lifting platform, 10 is the telescopic mechanism, 11 is the vibrator, 12 is the nut, 13 is the set screw, 14 is the support plate, and 15 is the waterproof coating layer. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments.

[0028] This embodiment includes an outer mold 1 and an inner mold 2, with a reinforcing steel frame 3 positioned between them. The outer mold 1 and inner mold 2 of this invention differ from existing external and internal formwork requiring support, and also from existing precast and assembled external and internal formwork. The outer mold 1 of this invention is prefabricated from ultra-high performance concrete (UHPC), and the inner mold 2 is also prefabricated from UHPC. The outer mold 1 is a U-shaped shell, and the inner mold 2 is a rectangular shell. Similar to conventional pipe gallery formwork, the four corners of the inner mold 2 are also chamfered. The dimensions of the outer mold 1 and inner mold 2 are manufactured according to the design drawings. Preferably, both the outer mold 1 and inner mold 2 are 3cm thick. The outer surface of the inner mold 2 is coated with a waterproof coating layer 15. The reinforcing steel frame 3 is located between the outer mold 1 and inner mold 2, and is rectangular in shape. The reinforcing steel frame 3 is made of ordinary threaded steel bars.

[0029] Several top supports 4 are prefabricated integrally on the top surface of the inner mold 2, serving to support the reinforcing steel cage 3. In this embodiment, the top supports 4 are short cylinders, also prefabricated from ultra-high performance concrete, and are integrally prefabricated with the inner mold 2. The top supports 4 support the reinforcing steel cage 3 upwards, ensuring a certain distance between the reinforcing steel cage 3 and the inner mold 2, guaranteeing that the concrete cover for the cast-in-place reinforcing steel meets the requirements of current regulations. The top supports 4 can be designed to be located at the intersection of the transverse and longitudinal reinforcing bars of the reinforcing steel cage 3.

[0030] Several holes 5 are provided on the bottom surface of the inner mold 2, penetrating the bottom surface of the inner mold 2. Nuts 12 are fixed downwards on the bottom surface of the holes 5, with the nuts 12 directly facing the holes 5 and attached to the bottom surface of the holes 5. The diameter of the holes 5 is smaller than the outer diameter of the nuts 12. The nuts 12 are threaded downwards to connect to set screws 13, which pass downwards through the reinforcing steel frame 3 and contact the outer mold 1. Nuts 12 and set screws 13 are used to support the inner mold 2 upwards. Preferably, a support plate 14 is provided on the bottom surface of the set screws 13 to increase the support area. The set screws 13 are preferably hexagonal socket set screws. By inserting a matching hexagonal wrench into the nut 12 through the holes 5, the set screws 13 can be turned to adjust their length, thereby adjusting the height of the support for the inner mold 2.

[0031] To facilitate vibration and reduce the workload of manual vibration, this invention also includes a vibration cart 6 suitable for the aforementioned template system. The vibration cart 6 is placed inside the inner mold 2 and includes a chassis 7 and wheels 8. An electric lifting platform 9 is mounted on the upper surface of the chassis 7. The electric lifting platform 9 is a commonly used lifting mechanism, which will not be described in detail here. A telescopic mechanism 10 is mounted on the lower surface of the chassis 7. The telescopic rod of the telescopic mechanism 10 can extend and retract downwards, and a vibrator 11 is fixed to the end of the telescopic rod. The vibrator 11 vibrates the bottom surface. Similarly, telescopic mechanisms 10 are mounted on both the left and right sides of the upper surface of the electric lifting platform 9. The telescopic rods of the telescopic mechanisms 10 can extend and retract left and right, and vibrators 11 are fixed to the ends of the telescopic rods, vibrating the left and right sides respectively. The vibrator 11 is preferably an attached flat vibrator, and the telescopic mechanism 10 can preferably be an electric telescopic rod or a telescopic hydraulic cylinder.

[0032] During construction, the outer formwork 1 is first hoisted and placed into the trench. Then, the inner formwork 2 is installed inside the reinforcing steel cage 3 outside the trench. The reinforcing steel cage 3 is supported by the top support 4. The length is adjusted by tightening the set screws 13 according to the designed spacing between the outer formwork 1 and the inner formwork 2. Then, the inner formwork 2 and the reinforcing steel cage 3 are placed into the outer formwork 1 together. If the height of the nut 12 and the set screw 13 does not meet the design requirements, an Allen wrench can be inserted into the nut 12 through the hole 5 of the inner formwork 2 to tighten the set screw 13 and fine-tune the height of the set screw 13 to meet the design requirements. After assembling the outer formwork 1, the reinforcing steel cage 3, and the inner formwork 2, concrete pouring begins. Then, the vibrating truck 6 can vibrate the concrete on the left, right, and bottom sides of the inner formwork 2 inside the inner formwork 2. The vibrating truck 6 can be moved to change the vibration position, and the electric lifting platform 9 can change the vibration height. The concrete at the top can be vibrated manually. Traditionally, after the concrete for pipe gallery is poured, the formwork can only be removed after the concrete has reached its strength, which usually takes about 14 days. However, the outer formwork 1 and inner formwork 2 of this invention are both made of ultra-high performance concrete material, so there is no need to remove the formwork. Moreover, the pipe gallery trench can be backfilled immediately after the concrete is poured without waiting for it to reach its strength. Furthermore, the integral pouring of concrete reduces splicing joints and reduces the occurrence of leakage problems.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; those skilled in the art should understand that modifications can still be made to the technical solutions described in the above embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal, characterized in that: The system includes an outer mold (1) and an inner mold (2). A steel reinforcement frame (3) is provided between the outer mold (1) and the inner mold (2). The outer mold (1) is a U-shaped shell made of precast ultra-high performance concrete, and the inner mold (2) is a rectangular shell made of precast ultra-high performance concrete. The four corners of the inner mold (2) are chamfered, and the outer surface of the inner mold (2) is coated with a waterproof coating layer (15). Several top supports (4) are precast on the top surface of the inner mold (2) and are used to support the steel reinforcement frame (3). Several holes (5) are provided on the bottom surface of the inner mold (2). Nuts (12) are fixed downward on the bottom surface of the holes (5). The nuts (12) are threaded downward to connect to set screws (13). The set screws (13) pass downward through the steel reinforcement frame (3) and contact the outer mold (1).

2. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 1, characterized in that: It also includes a vibratory compactor (6), which is placed inside the inner mold (2). The vibratory compactor (6) includes a chassis (7) and wheels (8). An electric lifting platform (9) is installed on the upper surface of the chassis (7). Telescopic mechanisms (10) are installed on the lower surface of the chassis (7) and on the left and right sides of the upper surface of the electric lifting platform (9). The end of the telescopic rod of the telescopic mechanism (10) is fixed with a vibrator (11).

3. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 1 or 2, characterized in that: The set screw (13) is an internal hexagon set screw.

4. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 1 or 2, characterized in that: The bottom surface of the set screw (13) is provided with a support plate (14).

5. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 1 or 2, characterized in that: The top support (4) is a short cylinder made of ultra-high performance concrete.

6. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 1 or 2, characterized in that: The outer mold (1) and the inner mold (2) are both 3cm thick.

7. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 2, characterized in that: The vibrator (11) is an attached flat plate vibrator.

8. The UHPC panel cast-in-place concrete municipal utility tunnel system without formwork removal according to claim 2, characterized in that: The telescopic mechanism (10) is an electric telescopic rod or a telescopic hydraulic cylinder.

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