Bridge prefabricated T-shaped middle beam and side beam adjustable assembly type general template

Abstract

The utility model discloses a bridge prefabricated T type middle beam, adjustable assembly type general template of side beam, including template system and adjusting system, the template system is T beam side beam template, and its panel thickness is 6mm, and the thickness of connecting plate is 12mm, and the rib adopts 10 type steel, and the support adopts 12 type steel and 14 type steel, the adjusting system is by transverse bulkhead head plate and flange adjusting plate, and the thickness of transverse bulkhead head plate and flange adjusting plate is 10mm, and the welding weld height between each component is 4 5mm, through the welding closure and removal of transverse bulkhead head plate, the welding assembly of flange adjusting plate, the present application solves the problem that two sets of independent templates need to be set up in the prefabricated T beam construction of existing prefabricated T beam, the universal adaptation of a set of templates is realized. The structural strength of the template is reliable, the bearing requirement of T beam prefabrication construction is satisfied, the construction quality hidden danger caused by template reform is avoided. The template installation and removal and reform process are simplified, the manpower and time input in the construction process is reduced, and the construction efficiency is improved.

Description

Technical Field

[0001] This utility model relates to the field of bridge engineering, specifically to an adjustable prefabricated universal template for precast T-shaped middle beams and side beams of bridges. Background Technology

[0002] In the construction of precast T-beams for bridge engineering, T-beams are generally divided into two types: middle beams and edge beams. Due to the difference in the arrangement of transverse diaphragms between the middle beams and edge beams—edge beams have no transverse diaphragms on the outer side of the bridge deck, while middle beams require transverse diaphragms on both sides; at the same time, the flange plate dimensions of the two are different, with the end portion of the flange on the outer side of the bridge deck of the edge beam being longer than that of the middle beam, resulting in the need for the design and fabrication of two separate sets of formwork for the middle beams and edge beams in the existing technology.

[0003] The use of two sets of formwork has significant drawbacks: firstly, the design and manufacturing costs of the formwork are high, increasing the total project investment; secondly, the transportation and storage of two sets of formwork require more space and resources, and frequent formwork replacements are necessary during construction, making the installation and dismantling process cumbersome, extending the construction period, and reducing construction efficiency; furthermore, the management and maintenance of multiple sets of formwork consumes additional manpower and time, further increasing construction costs. Therefore, there is an urgent need for a universal formwork that can be adapted to the prefabrication of both center beams and edge beams, solving the problems of poor formwork versatility, high construction costs, and low efficiency in existing technologies. Summary of the Invention

[0004] Therefore, this utility model provides an adjustable, prefabricated, universal formwork for precast T-shaped middle and side beams of bridges. It solves the problem in existing precast T-beam construction where two separate sets of formwork are required for the middle and side beams due to differences in diaphragm arrangement and flange dimensions, achieving universal compatibility with a single formwork. This ensures the reliable structural strength of the formwork, meeting the load-bearing requirements of T-beam precast construction and avoiding potential construction quality issues caused by formwork modifications. It simplifies the installation, dismantling, and modification process of the formwork, reducing manpower and time input during construction and improving construction efficiency. It also reduces the costs of formwork manufacturing, transportation, and storage, lowering the overall project cost.

[0005] This utility model is implemented as follows: It constructs an adjustable, prefabricated, universal template for precast T-shaped middle and side beams of bridges. Its features include a template system and an adjustment system. The template system is a T-beam side beam template with a panel thickness of 6mm, a connecting plate thickness of 12mm, ribs made of 10# steel, and supports made of 12# and 14# steel. The adjustment system consists of a diaphragm end plate and a flange adjustment plate, both with a thickness of 10mm. The weld height between components is 4-5mm. Through the welding and removal of the diaphragm end plate and the welding and assembly of the flange adjustment plate, the template can be switched and adapted during the precast construction of the T-beam side and middle beams.

[0006] According to the adjustable assembly universal template for prefabricated T-shaped middle beams and side beams of bridges described in this utility model, the feature is that: when the transverse diaphragm end plate is used for the prefabrication of the T-beam side beam, it closes the corresponding position on the outer side of the side beam where there is no transverse diaphragm.

[0007] According to the adjustable prefabricated universal template for bridge prefabrication T-shaped middle beams and side beams described in this utility model, the flange adjustment plate is used when the middle beam of the T-beam is prefabricated and is assembled at the flange template to compensate for the length difference between the flange ends of the side beam and the middle beam.

[0008] According to the adjustable prefabricated universal template for bridge prefabrication T-shaped middle beams and side beams described in this utility model, the feature is that: when in use, the side beams of the T-beam are prefabricated first by using the template system in conjunction with the diaphragm end plates, then the diaphragm end plates are removed and the flange adjustment plates are welded, and the middle beams of the T-beam are prefabricated after the template modification is completed.

[0009] This utility model has the following advantages: First, it is highly versatile. One set of templates can be easily modified to adapt to the prefabrication of T-beams, side beams, and middle beams, eliminating the need for two separate sets of templates and significantly reducing the cost of template investment.

[0010] Secondly, the structure is reliable in strength. Each component of the formwork system is made of plates and steel sections of a specific thickness. The parameters of the adjustment system components and welding seams are reasonable, which can meet the load-bearing requirements during construction and ensure the forming quality of the precast T-beams.

[0011] Third, it is easy to install, dismantle and modify. The adjustment system can be used to switch templates by simply welding and removing the diaphragm end plates and flange adjustment plates. The process is simple and convenient, saving time and labor costs for template replacement and improving construction efficiency.

[0012] Fourth, it reduces the total project cost by decreasing the costs of formwork production, transportation, storage, and maintenance, while also shortening the construction period and indirectly reducing other related expenses during the construction process, resulting in significant economic benefits. Attached Figure Description

[0013] Figure 1 This is the main view of the diaphragm end cap; Figure 2 This is a side view of the diaphragm end cap; Figure 3 This is the front view of the flange adjustment plate; Figure 4 This is a side view of the flange adjustment plate. Detailed Implementation

[0014] The following will be combined with the appendix Figures 1-4This utility model will be described in detail, and the technical solutions in the embodiments of this utility model will be clearly and completely described. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this utility model.

[0015] This utility model provides an adjustable, prefabricated, universal template for precast T-shaped middle and side beams of bridges, such as... Figures 1-4 As shown, the specific implementation is as follows: it includes a template system and an adjustment system; the template system is a T-beam side beam template, with a panel thickness of 6mm, a connecting plate thickness of 12mm, ribs made of 10# steel, and supports made of 12# and 14# steel; the adjustment system consists of a diaphragm end plate and a flange adjustment plate, both of which are 10mm thick, and the weld height between each component is 4-5mm; through the welding and sealing and removal of the diaphragm end plate and the welding and assembly of the flange adjustment plate, the template can be switched and adapted during the prefabrication construction of the T-beam side beam and the middle beam.

[0016] The adjustable prefabricated universal template for bridge prefabrication T-shaped middle beams and side beams described in this application; the diaphragm end plate is used to close the corresponding position on the outer side of the bridge deck where there is no diaphragm when the T-beam side beam is prefabricated.

[0017] The bridge prefabrication T-shaped middle beam and side beam adjustable assembly universal template described in this application; the flange adjustment plate is used when the middle beam of the T-beam is prefabricated, and is assembled at the flange template to compensate for the length difference between the flange ends of the side beam and the middle beam.

[0018] The bridge prefabrication T-shaped middle beam and side beam adjustable assembly universal template described in this application is used to first complete the prefabrication of the T-beam side beam by using the template system in conjunction with the transverse diaphragm end plate, then remove the transverse diaphragm end plate and weld the flange adjustment plate, and after completing the template modification, the T-beam middle beam is prefabricated.

[0019] The implementation process of this application is described in detail below; 1. Pre-construction preparation stage (1) Component inspection and acceptance: Check whether the specifications of all components of the template system and the adjustment system meet the design requirements. The panels (δ6mm steel plate), connecting plates (δ12mm steel plate), 10# steel ribs, and 12# and 14# steel supports of the template system must be free from deformation and cracks. The transverse diaphragm end plates and flange adjustment plates (both δ10mm steel plates) of the adjustment system must be dimensionally accurate, and the welding rods required for welding must be of the correct type to ensure that the weld can reach the height requirement of 4-5mm.

[0020] (2) Site and tool preparation: Clean the prefabrication site, ensure the ground is flat, and reserve space for template installation and storage; prepare welding equipment (such as manual arc welding machine), dismantling tools (such as gas cutting equipment, wrench), measuring tools (such as tape measure, level) and safety protection facilities (such as welding mask, anti-slip gloves).

[0021] (3) Pre-assembly of formwork: Pre-assemble the panels, connecting plates, steel ribs and supports of the formwork system according to the structural dimensions of the T-beam side beam, check whether the formwork splice gaps are tight and whether the structure is stable, and ensure that there is no risk of grout leakage.

[0022] 2. T-beam and side beam prefabrication construction stage (1) Template installation and fixing: The pre-assembled template system is hoisted to the prefabrication platform and fixed to the platform with brackets. The verticality and flatness of the template are adjusted to ensure that it meets the external dimensions requirements of the T-beam side beam.

[0023] (2) Installation of diaphragm end plates: Since there are no diaphragms on the outer side of the side beam bridge deck, the diaphragm end plates are installed by welding at the corresponding positions of the template. The height of the weld is controlled at 4-5mm to ensure that the end plates are firmly sealed to the template system and to avoid grout leakage when pouring concrete.

[0024] (3) Concrete pouring and curing: After the formwork installation is inspected and approved by the supervisor, pour the T-beam edge beam concrete into the formwork and compact it according to the specifications; after pouring, cover and cure it. After the concrete strength reaches the design requirements (usually more than 75% of the design strength), remove the formwork system (retain the main structure of the formwork and do not dismantle the core components).

[0025] 3. Template modification operation stage (1) Removal of diaphragm end plate: Use gas cutting equipment to cut and remove the diaphragm end plate along the weld seam, clean the welding slag and concrete residue on the template surface, and ensure that the template connection surface is flat and clean.

[0026] (2) Installation of flange adjustment plate: According to the size requirements of the middle beam flange plate, weld the flange adjustment plate at the end of the side beam flange template. The height of the weld should be kept at 4-5mm to ensure that the adjustment plate is firmly attached to the flange template, to compensate for the length difference between the end of the side beam and the middle beam flange, and to make the template fit the outer dimensions of the middle beam.

[0027] (3) Inspection of the modified template: Measure the overall dimensions of the modified template (such as flange length and reserved position of the diaphragm), check the connection strength between the adjustment system and the template system, and ensure that there is no loosening or deformation, so as to meet the load-bearing and forming requirements of the precast beam.

[0028] 4. T-beam middle beam prefabrication construction stage (1) Modified template installation: The modified general template is hoisted to the prefabrication platform. After adjustment and fixation, the sealing, verticality and flatness of the template are checked to ensure that the reserved position of the middle beam diaphragm is accurate.

[0029] (2) Concrete pouring and curing: The middle beam concrete is poured using the same process as the side beam prefabrication. After compaction, it is covered and cured. The formwork is removed after the strength reaches the standard.

[0030] (3) Reusable templates: If it is necessary to continue prefabricating side beams or middle beams, the above modification steps can be repeated (removing the flange adjustment plate, welding the transverse diaphragm end plate, or vice versa) to achieve cyclical adaptation of the templates.

[0031] 5. Template recycling and maintenance phase After construction is completed, the formwork system and adjustment system are disassembled, the components are derusted and protected against corrosion, and the steel supports and welds are inspected for damage. After timely repair, they are classified and stored for reuse in subsequent projects.

[0032] The utility value of this application will be explained below; 1. Economic value: Significantly reduce project costs: (1) Reduce formwork investment: One set of general formwork replaces two sets of special formwork, saving the design and manufacturing costs of one set of formwork (based on the cost of conventional T-beam formwork, it can save 30%-50% of the formwork purchase cost). (2) Reduce auxiliary costs: Reduce the transportation and storage costs of one set of formwork, save site space (no need to reserve storage areas for two sets of formwork separately); at the same time, reduce the manpower and material investment for formwork maintenance, and reduce long-term use costs. (3) Indirect cost savings: Shorten the construction cycle, reduce the delay in the construction period caused by formwork replacement and waiting, reduce indirect costs such as management, labor and machinery rental during the construction process, and improve the overall economic benefits of the project.

[0033] 2. Construction Value: Improving Efficiency and Convenience: (1) Simplifying Construction Process: Template modification only requires welding / removing two adjustment plates, which is simple and convenient to operate. There is no need for complicated disassembly or modification. Compared with replacing the entire template, it can save more than 60% of the switching time. (2) Reducing Operational Difficulty: The adjustment system is designed simply, and construction personnel can complete the modification without professional skills, reducing reliance on skilled workers and reducing labor costs and operational risks. (3) Improving Construction Efficiency: Avoiding frequent hoisting and installation of two sets of templates reduces construction interruption time and speeds up the T-beam prefabrication progress. It is especially suitable for large-scale, multi-span bridge projects and shortens the overall construction period.

[0034] 3. Quality Value: Ensuring the Forming Quality of Precast T-Beams: (1) Reliable Structural Strength: The template system uses δ6mm panels and 10#-14# steel supports. The adjustment system and weld parameters (δ10mm plates, 4-5mm welds) have been optimized, and the load-bearing capacity meets the construction requirements, avoiding T-beam size deviations and surface defects caused by template deformation and loosening. (2) High Forming Precision: The welded connection between the adjustment plate and the template system is tightly sealed, with no risk of grout leakage, ensuring the forming quality of the T-beam flanges and diaphragms, which meets the bridge engineering construction specifications. (3) Strong Quality Stability: The unified standard of one set of templates reduces the dimensional errors that may be caused by switching between two sets of templates, ensuring the consistency of the shape of the side beams and the middle beams, and improving the fit of bridge assembly.

[0035] 4. Management value: Optimize resource allocation: (1) Simplify material management: Only one template and two adjustment components need to be managed, reducing the workload of template inventory, stocktaking and maintenance, and reducing the complexity of material management.

[0036] (2) Improve resource utilization: The template can be reused in different batches of prefabricated edge beams and middle beams, and even adapted to T-beams of the same type but different spans (by fine-tuning the size of the plate), with a high resource reuse rate. (3) Reduce environmental pressure: Reduce the steel consumption of a set of templates, reduce energy consumption and carbon emissions in the production process; at the same time, reduce construction waste after the templates are discarded, which is in line with the concept of green construction.

[0037] 5. Industry Value: Driving the Upgrading of Construction Technology It provides a "universal and modular" formwork solution for the construction of precast T-beams, solving the long-standing pain points of "poor formwork versatility and high cost" in the industry. It can provide a reference for similar bridge projects and promote the standardization and efficiency of precast component construction technology.

[0038] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A universal, adjustable, prefabricated template for precast T-shaped middle and side beams of bridges, characterized in that; The system includes a template system and an adjustment system. The template system is a T-beam edge beam template with a panel thickness of 6mm, a connecting plate thickness of 12mm, ribs made of 10# steel, and supports made of 12# and 14# steel. The adjustment system consists of a diaphragm end plate and a flange adjustment plate, both of which are 10mm thick. The weld height between the components is 4-5mm. By welding and removing the diaphragm end plate and welding and assembling the flange adjustment plate, the template can be switched and adapted during the prefabrication of the T-beam edge beam and the middle beam.

2. The adjustable prefabricated universal template for bridge precast T-shaped middle beams and side beams according to claim 1, characterized in that: The diaphragm end plate is used to close the corresponding position on the outer side of the bridge deck of the T-beam when the side beam is prefabricated and there is no diaphragm.

3. The adjustable prefabricated universal template for bridge precast T-shaped middle beams and side beams according to claim 1, characterized in that: The flange adjustment plate is used during the prefabrication of the middle beam of the T-beam, and is assembled at the flange template to compensate for the length difference between the flange ends of the side beam and the middle beam.

4. The adjustable prefabricated universal template for bridge precast T-shaped middle beams and side beams according to claim 1, characterized in that: When using it, the T-beam side beams are prefabricated first by using the template system in conjunction with the diaphragm end plates. Then, the diaphragm end plates are removed and the flange adjustment plates are welded. After the template modification is completed, the T-beam middle beams are prefabricated.

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