RU2830689C1 - System for continuous erection of massive reinforced concrete and concrete structures - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to devices for erection of concrete and reinforced concrete structures of high height. System for continuous erection of massive reinforced concrete and concrete structures includes at least one vertical fixed structure in the form of a mast and a movable structure comprising a scaffold on which a sliding formwork is fixed. Fixed and movable structures are connected by means of a lifting unit made with a thrust and support beams, combined by at least one hydraulic cylinder of the hydraulic system, to provide for the possibility of synchronous lifting of the movable structure along the mast for concreting walls and columns at a given technological speed of up to 120 mm/h.

EFFECT: providing continuous concreting of the structure from beginning to complete completion, uniform lifting of sliding formwork, reducing construction time, reducing labor intensity of works.

8 cl, 9 dwg

Description

Field of technology

The claimed technical solution is applied in the field of construction during the erection of high-rise concrete and reinforced concrete structures for industrial, civil, particularly complex unique buildings and structures, with increased requirements, such as the absence of working seams.

State of the art

A method for erecting structural elements of a building/structure from monolithic reinforced concrete and technological equipment for its implementation are known (RU2685586C1 dated 23.10.2017, application: 2017137181, IPC class E04B1/16, E04G11/20, E04G9/02), where the equipment includes movable formwork that contains lifting jacks with posts enclosed in sleeves, on which U-shaped jack frames are installed. Holders of vertical formwork shields and outriggers are fixed with the possibility of movement at the base of the jack frame posts. During the execution of work, the formwork is supported on previously erected structures by means of lifting jack posts, while the sleeves enclosing the posts are given a rotational movement. Next, the outriggers of the jack frames are installed on the newly erected structures, the jack stands are removed together with the sleeves, and concrete is placed in the formed cavities. The formwork is reinstalled on the erected structures using the jacks, and the cycle is repeated.

The disadvantage of the technical solution is the impossibility of using the specified method for the construction of massive reinforced concrete structures with the possibility of continuous concreting, due to:

- mutual arrangement of formwork panels;

- dependence of the jack lift on the wall structure;

- the inability to bypass the reinforcement outlets, which must be left in the wall;

- the impossibility of simultaneously performing reinforcement and installing embedded parts while concreting.

Another method for erecting monolithic three-layer enclosing and internal walls of a building and a formwork system for its implementation is known (RU2401918C2 dated 22.07.2008, application 2008130432, IPC class E04B 2/84, E04G 11/00) containing facing, heat-insulating and structural layers using enclosing, heat-insulating, structural and corner formwork, vertically movable along racks and equipped with a lifting mechanism and a mechanism for feeding and removing panels, associated with the installation of formwork on a horizontal platform, checking the verticality of the formwork panels, laying a layer of molded mixture into the formwork to a given height, compacting it, achieving a given strength with the mixture, removing the formwork panels from the wall and lifting them to a new level, bringing the formwork panels to the wall, repeating the described cycle until the walls are erected to a height floors. The frames of the enclosing and internal formwork are rigidly connected with the frames of the corner formwork into a single formwork system, the lifting of which to a new level is carried out along the racks in a series of synchronous small steps using a short-stroke step lifting mechanism; the enclosing formwork is made in two levels. In this case, the panels of the upper level of the formwork form the heat-insulating layer of the three-layer enclosing wall, and the panels of the lower level of the formwork form the facing and structural layers, and simultaneously form all three layers on two levels, while the heat-insulating layer of the upper level rises above the facing and structural layers of the lower level. The posts in the process of lifting the formwork system from one level to another within the floor being erected rest on the interfloor slab of the previous floor, and when forming the interfloor slab of a given floor, the formwork system is raised above the plane of the upper cut of the structural layer of the wall of a given floor and fixed in the raised position with supports resting on the upper cut of the structural layer and the formwork system, then the posts are pulled up, freeing up space for forming the interfloor slab. After that, the interfloor slab itself is formed, we concrete it with the structural layer, the posts are lowered onto the surface of the newly formed interfloor slab and the supports are removed, then they begin forming the walls of the next floor. The specified technical solution is taken as a prototype.

The disadvantage of the technical solution is the lack of the possibility of continuous concreting, since stops are made in the area of interfloor ceilings and the pillars subsequently rest on these ceilings. In addition, as a result of stops, a working joint is formed in the concrete, which affects the integrity of the structure.

The applicant's analysis of the state of the art, including a search of patent and scientific and technical sources of information and the identification of sources containing information on analogues of the claimed technical solution, made it possible to establish that the applicant did not find an analogue characterized by the feature of identity (identical) to all essential features of the claimed invention, which corresponds to the criterion of "novelty".

The invention criterion of "industrial applicability" is confirmed by the fact that the proposed technical solution provides a fundamentally different method of use in construction, namely a system of continuous construction of building walls without the formation of working joints.

The objective of the claimed technical solution is to develop a system for the continuous construction of massive reinforced concrete and/or concrete structures using lifting equipment (SNV-MZhBK), where the quality of the finished concrete structure is achieved by reducing the number of working joints and cracks on the surface, due to continuous concreting.

Additional objectives of the claimed technical solution are:

- ensuring work with panel formwork of any manufacturer and, if necessary, with formwork manufactured on site, while its use will not require significant changes to the design;

- reducing the cost and speeding up work due to its round-the-clock management;

- reducing the time of use of machines and mechanisms;

- no need to assemble, disassemble and rearrange formwork and standard scaffolding (scaffolding, towers, etc.);

- additional processing and preparation of surfaces of working joints and formwork surfaces required for further concreting;

- absence of periods of work stoppages necessary for the concrete to gain strength in the section being erected.

Disclosure of the essence of the technical solution

The technical solution to the above problem is the development of a system for the continuous construction of massive reinforced concrete and concrete structures, including at least one vertical fixed structure in the form of a mast and a movable structure containing scaffolding on which sliding formwork is fixed, wherein the fixed and movable structures are connected by means of a lifting unit made with thrust and support beams, united by at least one hydraulic cylinder of the hydraulic system, to ensure the possibility of synchronously with a given technological speed of up to 120 mm/hour to carry out vertical lifting of the movable structure along the mast for concreting walls and columns. The specified technical solution ensures continuous concreting during the construction of the building structure.

A possible technical solution is one in which the lifting equipment is a system of hydraulic cylinders, hydraulic stations, interconnected by high-pressure hoses (HPH), and performing the functions of synchronous lifting of formwork scaffolds. This technical solution ensures uniform performance of work during the construction of buildings and structures, while avoiding the formation of working seams.

A possible technical solution is one in which the hydraulic system is at least one hydraulic station with an electric drive, installed on lifting scaffolds and connected to hydraulic cylinders by high-pressure hoses. This technical solution ensures synchronous lifting of scaffolds and formwork.

A possible technical solution variant is one in which the hydraulic system is at least two hydraulic cylinders installed and secured via support blocks on the movable scaffolding on one side and the fixed mast on the other, which are driven by a hydraulic pump. The specified technical solution ensures synchronous lifting of the scaffolding and formwork.

A possible technical solution is one in which the hydraulic system consists of at least two jacks, which are driven by an oil station, through high-pressure hoses, by supplying oil under high pressure by an oil pump. This technical solution ensures synchronous lifting of scaffolding and formwork.

A possible technical solution is where the sliding formwork is a protective structure installed on movable scaffolding and secured to a retractable console with bolts, a screw turnbuckle and designed for laying concrete mix. This technical solution ensures uniform concreting over the entire height during the construction of the required structures, such as buildings and structures.

A possible technical solution is one in which the working scaffolding is a metal frame covered with wooden flooring, fastening elements such as a retractable console, stop elements and formwork adjustments, and is designed for concrete work at height. This technical solution ensures a stable formwork position throughout the work.

A possible technical solution is one in which the fixed part consists of at least one reinforced concrete slab and one mast, secured together with anchor bolts. This technical solution makes it possible to install the mast in a vertical position and maintain its stability.

A possible technical solution is one in which the movable part consists of at least a lifting unit, formwork panels, united into one plane, using formwork fastening elements, a hydraulic system, as well as flooring and fencing, with the unification being carried out using bolted connections. The specified technical solution provides the possibility of using it as a single rigid structure.

A possible technical solution is one in which the lifting unit is a thrust and support beam connected by a hydraulic cylinder with which it moves vertically. This technical solution makes it possible to move the structure up and down.

Brief list of drawings

Additionally, we note that the figures attached in Fig. 1-9 show the most preferred embodiment of the technical solution and cannot be considered as a limitation of the content of the technical solution, which also includes other embodiments.

Fig. 1 shows the general view of the SNV-MZhBK,

Fig. 2 - shows a mast, which is a vertical fixed structure and is made mainly from IPRS inventory structures and a metal beam, with holes drilled according to the design for fastening support tables (Fig. 7) using metal bolts and nuts or other metal rods of a suitable diameter with a thread for a nut.

Fig. 3 - shows the scaffold frame, which is a metal volumetric structure and is made mainly of steel beams with ribs and steel angles, which are secured together using metal bolts and nuts, and the scaffold frame itself is fastened to the lifting unit and hung on the mast.

Fig. 4 - a lifting unit, which is a metal structure and is made mainly of steel beams, steel plates, steel angles, which are secured together by welding, metal bolts with nuts, and a hydraulic cylinder (Fig. 5), which is secured freely (allowing the hydraulic cylinder to move along the axis of the holes in the eye and the support table) to the support tables (Fig. 7) with metal bolts and nuts or other metal rods of a suitable diameter with a thread for the nut.

Fig. 5 - a hydraulic cylinder, which is a factory hydraulic device, which is designed for lifting and lowering loads and is driven by a hydraulic oil station.

Fig. 6 - lifting frame of hydraulic cylinders (Fig. 5), which is a metal structure and is made mainly of steel beams, steel angles, which are secured together by welding, metal bolts with nuts.

Fig. 7 - a support table, which is a metal structure made primarily of steel angle and sheet metal with holes for fasteners (bolts or other metal rods of suitable diameter with threads for a nut), which are secured together by welding, and which is connected to a hydraulic cylinder, which is secured in the support table using bolts and nuts or other metal rods of suitable diameter with threads for a nut.

Fig. 8 - formwork shield (pos. 5), which is an inventory shield made mainly of metal and plywood.

Fig. 9 - formwork fastening, which is a metal structure made mainly of metal square pipes, metal angles, metal channels, metal sheets; inventory screw turnbuckle, while the fastening itself occurs due to inventory formwork tie screws and nuts.

Where

Fixed part:

pos. 1 is the mast (Fig. 2),

Moving part:

pos. 2 is the scaffold frame (Fig. 3);

pos. 3 - lifting frame (Fig. 4);

pos. 4 - screw stop, allowing adjustment of the position of the formwork shield;

pos. 5 - formwork, which is a prefabricated panel, factory-made, made mainly of metal and plywood;

pos. 6 - lifting frame of hydraulic cylinders (Fig. 6);

pos. 7 - support table (Fig. 7);

pos. 8 - hydraulic cylinder (Fig. 5).

pos. 9 - a limiter, which is a product made of a corner and a threaded rod, necessary for adjusting the position of the movable part on the mast (Fig. 2).

Additionally, we note that the formwork (Fig. 6) is secured using (pos. 4) the formwork fastening (Fig. 5) to the scaffold frame (Fig. 3).

The lumber flooring is laid on the scaffold frames (Fig. 3), the fencing made of metal pipes, rods, and plates, and the hydraulic pump station are not shown in the Fig.

Implementation of a technical solution

In the technical solution, the following concepts are understood under the terms used:

lifting equipment is a hydraulic system designed for vertical lifting and horizontal movement of loads, mechanisms, bridge spans, consisting of a hydraulic station with an electric drive, hydraulic cylinders or jacks, which are driven by an oil station through high-pressure hoses;

mast - a supporting vertical metal structure that bears vertical and partially horizontal loads and is part of a column;

formwork - an enclosing structure for laying concrete mixture;

a fixed part is a part of a structure that remains in a fixed position during operation or maintenance;

a movable part is a part of a structure that moves relative to a stationary part when a pushing force is applied to it, which is carried out using lifting equipment (a hydraulic system).

SNV-MZhBK conventionally consists of 2 main parts:

fixed - consisting of reinforced concrete slabs and a mast (Fig. 2);

movable - consisting of scaffold frames (Fig. 3), a lifting unit (Fig. 4), formwork panels (Fig. 8), formwork fastenings (Fig. 9), a hydraulic system, as well as flooring and fencing.

The fixed and movable parts form a single structure, united by a lifting unit (Fig. 4) allowing synchronously, with a given technological speed of up to 200 mm/hour, to lift the movable part, the sliding formwork structure and perform the necessary work at height associated with concreting the wall and column structures. The horizontal position of the parts relative to each other is adjusted using a limiter (Fig. 4 pos. 4), installed on the upper beam of the lifting frame (Fig. 6).

The lifting unit itself (Fig. 4) is a thrust and support beam connected by a hydraulic cylinder, with the help of which it moves vertically.

The fixed part consists of at least one reinforced concrete slab and one mast (item 1), secured together with anchor bolts.

The movable part consists of at least a lifting unit (Fig. 4), formwork panels connected into one plane using fastening elements, a hydraulic system, as well as flooring and fencing, with the connection being carried out using bolted connections.

The start of concreting using SNV-MZhBK is carried out from a mark in the range from 0.5 to 1.5 meters, in the preferred embodiment - +1.000 meters from the bottom of the base of the structure being concreted, for which purpose a number of inventory formwork panels (Fig. 8) 1 m high are installed in the lower part of this structure, along the perimeter, and inventory formwork panels (Fig. 8) of the movable part are installed on top of the retractable console, installed on movable scaffolding, secured to the retractable console with bolts and a screw turnbuckle.

The movable part of the SNV-MZhBK moves upwards along the fixed part during the work, and downwards after concreting is completed. The movable part is driven by a hydraulic system (only hydraulic cylinders are shown in the fig.). The use of hydraulic cylinders (fig. 5) allows for smooth, uniform lifting of the entire movable part.

The hydraulic system itself is available in several versions:

- first version: at least one hydraulic station with an electric drive, installed on lifting scaffolds and connected to hydraulic cylinders by high-pressure hoses;

- second version: a hydraulic system consisting of at least two hydraulic cylinders installed and secured through support blocks on the movable scaffolding on one side and the fixed mast on the other, which are driven by a hydraulic pump;

- the third version: consists of at least two jacks, which are driven by an oil station, through high-pressure hoses, by supplying oil under high pressure by an oil pump.

The SNV-MZhBK is raised and lowered along vertically installed masts (Fig. 2), using a hydraulic system (not shown in the Fig.). The hydraulic cylinders (Fig. 5) rest on the lower support table (Fig. 7), fixed to the mast column (Fig. 2) using a bolted connection.

Next, hydraulic cylinders (Fig. 7) perform a smooth lift of the movable part along the mast column (Fig. 2); concreting and, if necessary, reinforcement of the structure are performed in parallel with the lift.

The number of fixed and movable parts depends on the need to ensure uniform lifting of the scaffolding, for example, for a structure 100 by 100 meters wide, 40 fixed parts and 400 meters of movable parts are required, and for a building 6 by 6 meters wide, 4 fixed parts and 12 meters of movable parts are required.

SNV-MZhBK is built on the principle of cyclic lifting of loads.

A detailed movement cycle consists of the following steps:

1. Fastening the lower support tables (Fig. 7) to the mast columns (Fig. 2) using a bolted connection;

2. The lifting speed of the moving part is in the range of 50 to 200 mm/hour and can be increased;

3. Fastening the upper support tables (Fig. 7) after lifting to a given height using a bolted connection;

4. Disconnecting the lower support tables (Fig. 7) from the masts (Fig. 2);

5. The reverse stroke of the hydraulic cylinders raises the lower support tables (Fig. 5) by 300 mm.

6. Fastening the lower support tables (Fig. 7) to the mast columns (Fig. 2) using a bolted connection;

7. Unfasten the upper support tables (Fig. 7) from the mast columns (Fig. 2) and continue lifting the movable part.

Then the cycle is repeated in order according to points 2-7.

The implementation of the technical solution is explained using the example of the construction of a massive concrete preparation of the building of the storage of fresh fuel and radioactive waste of the Leningrad NPP-2, where it was necessary to erect the said structure 12 meters high and during the construction of a reinforced concrete model 8 meters high. During the construction of the structure, concrete was supplied continuously, which allowed saving 50% of the time for its construction. Due to the use of continuous concrete supply, the number of working seams was reduced, which increased the quality of the monolithic structure, its water resistance, and therefore durability. Continuous work helps to carry out the work in a more organized and coordinated manner, since the entire process is tied into a single whole.

The claimed technical solution, namely the system of continuous construction of massive reinforced concrete and concrete structures using lifting equipment (SNV-MZhBK) ensuring uniform lifting of the sliding formwork, continuous concreting of the structure from start to complete completion, safe execution of works, reduction of construction time, reduction of labor intensity of works.

Claims (8)

1. A system for the continuous construction of massive reinforced concrete and concrete structures, including at least one vertical fixed structure in the form of a mast and a movable structure containing scaffolding on which sliding formwork is secured, wherein the fixed and movable structures are connected by means of a lifting unit made with thrust and support beams, united by at least one hydraulic cylinder of a hydraulic system to ensure the ability to synchronously, with a given technological speed of up to 120 mm/hour, carry out vertical lifting of the movable structure along the mast for concreting walls and columns. 2. The system according to item 1, characterized in that the hydraulic system is designed as a system of hydraulic cylinders, hydraulic stations, connected to each other using high-pressure hoses (HPH) for synchronous lifting of scaffolding and formwork. 3. The system according to item 1, characterized in that the hydraulic system is made in the form of at least one hydraulic station with an electric drive, installed on scaffolding and connected to hydraulic cylinders by high-pressure hoses. 4. The system according to item 1, characterized in that the hydraulic system contains at least two hydraulic cylinders driven by a hydraulic pump, installed and secured via support blocks on movable scaffolds on one side and a fixed mast on the other. 5. The system according to item 1, characterized in that the hydraulic system contains at least two jacks for driving them by the oil station pump through high-pressure hoses. 6. The system according to item 1, characterized in that the sliding formwork, installed on the movable scaffolding, is secured to the retractable console with bolts and a screw turnbuckle. 7. The system according to item 1, characterized in that the scaffolding is made in the form of a metal frame covered with wooden flooring, with a retractable console, support elements and formwork adjustments. 8. The system according to item 1, characterized in that the elements of the movable structure are connected by means of bolted connections.