1． Process principle
The new guide rail type hydraulic climbing formwork is still a formwork and climbing frame mutual climbing system, and its biggest feature is that the climbing frame can be inserted into the decoration decoration operation during the structural construction, that is, the climbing mold climbing frame joint rises to complete the structural construction, and the separate body descends for decoration and decoration operations, see the figure below.
Figure: New guide rail type hydraulic climbing formwork process flow
(a) The concrete pouring of the wall is completed; (b) the mold is disassembled; (c) the climbing frame is lifted;
(d) Dismantling large formwork and installing hanging basket lifting equipment;
1- Large formwork; 2- Rail; 3- Upper shelf; 4- Lower shelf
2． Construction and composition
The new lifting and climbing die is mainly composed of four parts: attachment device, guide rail, lifting and climbing box and frame system, formwork system or working platform system, hydraulic lifting and control system, hanging basket equipment system, safety protection system and anti-fall device (below). The main parameters of the new lifting and climbing die are as follows:
The frame support span is ≤8m
Frame height 9.8~13.5m (depending on the height of the structure)
The frame width ≤ 2.25m
The moving distance of the formwork trolley is 0.75m
The walking distance is 1.85~2.7m
Steps 4 to 6
The number of working layers and the construction load ≤ 1.5kN/m2 for the top layer, 3 kN/m2 for the middle layer ≤, and 1kN/m2 for the bottom layer ≤
Figure: Schematic diagram of the construction of the new guide rail type hydraulic climbing die
1- Platform plate; 2- Outer formwork; 3- Attached back lintel; 4- Locking hook; 5- Formwork high and low adjustment device; 6- Anti-fall device;
7- Bolt through the wall; 8- Attached wall device; 9- Hydraulic cylinder; 10- Climbing box; 11- Upper frame outrigger; 12-Rail;
13-Formwork support frame; 14-Adjusting legs; 15-Formwork translation device; 16-Upper frame; 17-Horizontal beam frame;
18- Lower frame; 19- Lower frame hoist; 20- Railing; 21- Skirting board
(1) Frame system
The frame body of the new lifting formwork is mainly composed of the upper bearing frame and the lower bearing frame in the vertical direction; its horizontal is mainly composed of horizontal beam frame and corresponding frame pipe.
1) Upper bearing frame
The upper bearing frame is the main bearing frame of the climbing die climbing frame in the vertical direction, which is composed of a triangular structure (for equipment with template climbing) or rectangular frame (for equipment without template climbing) and components such as the wall adjustment legs and the upper climbing box shaft seat.
On both sides of the bearing frame, there are ear plates for connecting the horizontal beam frame, and at the outriggers, there are guide-type open splints for lifting the rails and preventing the frame from overturning.
2) Lower bearing frame
The lower bearing frame is a climbing frame in the vertical direction of the secondary bearing frame, which is suspended by a pin shaft at the lower end of the main bearing frame. Like the upper bearing frame, it is equipped with ear plates on both sides for connecting the horizontal beam frame. After the current bearing frame and the corresponding horizontal beam frame are assembled, they are hung at the lower end of the main bearing frame, referred to as the hanging basket hanging rack.
3) Horizontal beam frame
In the lateral side of the new lifting die frame, the inner and outer sides of the adjacent vertical bearing frame are respectively equipped with truss horizontal beam frames, which are connected together by steel pipe fasteners and laid with leg plates in the corresponding positions. According to the height and use requirements of the bearing frame, there can be a multi-channel horizontal beam frame, which is also known as a horizontal frame beam frame.
(2) Template system or working platform system
The formwork system located on the triangular support frame is composed of a newly designed large formwork without a back and a corresponding formwork support device, a height adjustment device, a vertical adjustment device and a formwork horizontal moving trolley.
For the climbing die climbing frame without a template climb, the working platform system composed of vertical dissector frame, horizontal horizontal beam frame, etc. is installed on the main bearing frame.
(3) Hanging basket equipment system
The hanging basket equipment system is the hanging basket equipment and corresponding control system installed in the lower part of the main bearing frame when the lower frame of the climbing frame is used as the hanging basket hanger, mainly including the basket hoist, pulley, wire rope, safety lock, etc.
(4) Attachment device
It is not only the bearing support attached to the construction project or construction engineering structure of the new lifting mold frame, but also the guiding device and anti-overturning device when the new lifting mold frame is lifted. When the thickness of the attached building structure is small, the embedded steel casing is used in the building structure; when the attached structure thickness is large, the embedded kit and the corresponding components are used in the concrete structure.
(5) Guide rail and lifting climbing box
The lifting rail is H-shaped steel, the length of which is greater than the height of the two standard floors or adjacent two floors, the inner side of the top of the H-shaped steel is welded with a hook seat with a slope, and the upper group of the outer side of the H-shaped steel is welded with the support block (step block) and the guide block for lifting and lowering the climbing box, and the distance between the support block or the guide block matches the stroke.
The climbing box for lifting is divided into an upper climb box and a lower climb box, which is mainly composed of a box body, a cam balance (bearing block), a guide wheel, a positioning lock, a connecting pin shaft and other components.
(6) Anti-fall device
In accordance with the relevant provisions and requirements of the attached lifting scaffolding, the anti-fall device of the new lifting mold frame is designed by using prestressed anchor clamp technology, which is mainly composed of supporting anchor seats, lock seats, steel hinges and protective pipes. The upper end of the anti-fall device is a fixed end, installed at the upper end of the lifting guide rail; the locking end is fixed at the end of the main beam of the main bearing frame, when the main bearing frame falls relative to the lifting rail, the spring pushes the clamp to wedge the steel strand, so that the main bearing frame stops falling relative to the lifting rail, and the lifting guide rail has two upper and lower stops and two attachment supports locked, which can ensure that the lifting rail is reliably connected with the wall and ensures safety.
(7) Hydraulic lifting equipment and control system
The power equipment for lifting and lowering of the new lifting mold frame is mainly composed of a hydraulic cylinder and a corresponding pumping station. The hydraulic cylinder installed between the up and down climbing tanks is a removable portable cylinder with a two-way hydraulic lock, and the hydraulic pumping station can be a portable or centralized pumping station.
There are two kinds of control systems for lifting and lowering: one is a manual control system, and the other is an automatic control system composed of programmable controllers.
(8) Security protection system
In accordance with the requirements of high-altitude safe operation and operation, a strong and durable steel scaffold board or wooden scaffold board is provided in the corresponding working platform part of the frame, and the corresponding safety protection devices such as guardrails, guard rods, protective plates and safety nets are set up.
3． Technical characteristics
Compared with the existing climbing die and climbing frame, the new lifting die frame has the following main technical characteristics:
(1) The combination of split frame system, novel concept, simple structure, clear force, more functions. As shown in the figure, the frame body of the new lifting mold frame is composed of three levels of frame or a three-part frame: (1) the main frame (upper frame) and the corresponding horizontal beam frame, etc. The main frame (upper frame) system (upper frame system) ;(2) The lower frame (lower bearing frame) hanging in the lower part of the main bearing frame and the corresponding horizontal beam frame are composed of the lower frame (hanging basket frame) system; (3) above the main frame is the template system or the upper working platform system. During the construction of the structure, the lower frame system is hung by pins on the lower side of the upper frame and integrated with the upper frame body, and climbs with the climbing of the upper frame, that is, the climbing frame body climbs; when the construction project is constructed to a certain height and the lower structure needs to be decorated and decorated, the hanging basket equipment system can be installed to make the lower frame of the climbing frame separate from the upper frame body, that is, the climbing frame body is descended separately to meet the requirements of the use of the lower structure to carry out external decoration and decoration operations in advance. At the same time, during the construction of the first layer structure, the upper shelf can be installed first and the lower shelf body can be temporarily installed, so that it can be put into use as early as possible, and then installed and used when the components of the lower frame are installed. In addition, when there is no need to install the lower frame to meet the construction needs, only the upper frame and the upper working platform system or formwork system can be put into use. Thus, the frame system is simpler and more applicable.
(2) Multi-functional attachment device with attachment, guidance and anti-overturning. The attachment device is an attachment fixture that directly connects with the engineering structure and bears and transmits the new lifting mold frame, as well as the attachment fixture of the construction load and wind load, and at the same time is the guide device and anti-overturning device when the rail and the frame are lifted. The attachment device is connected to the wall as shown in the figure above.
(3) Robust guide lifting device and automatic climbing mutual climbing technology. In the high strength, stiffness of the H-shaped steel guide rail group welding with a strong and reliable guide rail hook seat and a strong and reliable step bearing block and guide plate for the lifting and lowering of the climbing box, with a cam pendulum and can automatically reset the climbing box attachment to the H-type guide rail, and through the connection shaft at the top of the upper climbing box and the main bearing frame of the frame are organically integrated, the guide rail and the climbing mold climbing frame through the hydraulic cylinder installed between the upper and lower climbing box and the corresponding pump station to achieve automatic lifting and lowering between the frame and the rail.
(4) Flexible and applicable large formwork and lifting scaffolding integration technology. In the new type of lifting mold frame with automatic climbing of the formwork, in order to be able to adapt to the placement and use requirements of various templates, on the vertical support frame of the template that moves horizontally with the moving trolley and has the function of formwork height adjustment and verticality adjustment, the formwork additional support frame is specially set up, so that various types of all-steel large formwork and various types of assembled steel and wood bamboo formwork can be adapted.
120 series no back lavender light large formwork, the longitudinal and horizontal primary keel of the template and the side keel of the same surface height, when the template panel is 6mm thick steel panel, the template keel selects 120×60×2.5 (3.0) and 120×40×2.5 (3.0) square steel pipe, when the panel selects 18 ~ 20mm thick composite wood (bamboo) plywood, the choice of 100×60× 2.5 (3.0) and 100×40×2.5 (3.0) square steel pipe. These two are collectively referred to as the 120 series (one is 126, one is 118 or 120) without a back of the large formwork, the self-weight of 70 ~ 90kg / m2, can resist the side pressure of 70 ~ 80kN / m2, not only can meet the requirements of clear water concrete construction, in the formwork configuration can make the number of bolts through the wall reduce, shorten the length; in the climbing frame configuration due to the light weight of the formwork can increase the distance between the machine positions, thereby reducing the number of climbing frame positions.
(5) Electromechanical and hydraulic integration technology, simple and applicable manual synchronous control and modern automatic control technology, can make the climbing die climbing frame rise and fall smoothly.
(6) There is a hanging basket function with equipment. According to the progress of the project and the need to install a gondola hoist, safety lock, wire rope and electronic control system on the frame, so that the lower frame and the main bearing frame are separated, the lower frame body is used as the hanging basket frame for external decoration and decoration construction, and when the lower frame body is used as a hanging basket frame construction, each hanging basket frame can be connected into one to achieve multi-motor synchronous control and lifting.
(7) Multi-channel complete safety devices and safety measures. In order to ensure the safety of the lifting die frame during the lifting process, a safe and reliable H-type steel guide rail and a new lifting mechanism with a cam pendulum climbing box are adopted.
In order to prevent the rupture of the hydraulic cylinder tubing, a hydraulic safety lock is provided on the hydraulic cylinder.
In order to ensure that nothing goes wrong, a special fall prevention device is set up.
(8) The height of the frame is small, the transmission line is clear, the group frame climbs flexibly, and the installation and disassembly at low altitude and low place.