Installation instructions for tunnel lining formwork trolley

In order to make the formwork trolley properly use its performance, the installation work instruction is specially formulated. This instruction is based on the factory and field installation. Installation in the cave should be guided according to specific conditions and facilities, and site conditions with reference to these measures.

First, technical equipment

1. Familiar with the design drawings and relevant technical information of the trolley, and have a clear and accurate knowledge of the structural dimensions, connection methods, and related part numbers of the trolley.

2. First of all, inspect the site and determine the installation plan, and carry out the necessary design and calculation of the main lifting equipment and auxiliary facilities, such as the installation space of the trolley, lifting equipment, floor space and activity space. The hoisting ring equipment and trolley parts installed in the cave are placed and placed.

3. Prepare the installation worksheet, determine the technical requirements for the installation schedule, and determine the operating personnel and the person in charge of the project (cooperating personnel of the construction party).

The tunnel concrete maintenance formwork

Second, equipment and tools preparation

1. Determine the feasible location of the lifting equipment on site, and the construction can be carried out under the condition that the lifting height and lifting tonnage are satisfied.

2. Strictly check the lifting equipment, such as the specifications, length, quantity of the wire rope, the condition of the rope ring, the wear condition, the condition of the wire rope card, the ring and other tools. If any problems are found, replace them in time.

Third, check the installation of trolley components

1. Whether there is collision deformation, loss, or mishandling of steel structural components during transportation.

2. Whether all kinds of accessories of hydraulic walking and supporting parts are complete.

3. Whether the specifications and quantity of the bolts used for fastening are complete. If there are problems, corresponding measures and methods should be taken to deal with them in a timely manner.

Fourth, the safety inspection and protection of the installation site

1. Reasonable placement of various equipment, materials and trolley components.

2. The installation of power, voltage, circuit is in line with the requirements of safe power consumption, whether centralized control.

3. The safety distance of the oxygen and acetylene tanks is 6 meters and the line has no leakage. Check the oxygen and acetylene pipes for leakage and maintain a safe operating distance.

Warning signs or guards shall be set up at the installation site. Unemployed persons and vehicles are strictly prohibited from entering the installation site. Installation personnel who enter the site must wear safety helmets and must wear safety ropes. Installation technicians must conduct safety talks before installation and during installation. Safety supervision and inspection.

Tunnel formwork channel

Fifth, when the trolley is installed

First of all, it is necessary to ensure the level of the rail surface, and the contact surface at the bottom of the rail should be rigid to prevent the trolley from sinking after installation and causing the trolley’s diagonal error.

Sixth, install walking beam

1. Determine the walking box assembly on the rail, make the lifting box axis of the walking box perpendicular to the center line of the rail, and support the four sides of the walking box firmly. Hang a walking beam vertically down above the two walking boxes, so that the axes of the lifting ears at both ends of the walking beam coincide with the axes of the active and passive box lifting ears respectively, penetrate the connecting pin and the anti-channeling cotter pin, and Triangular supports are reinforced on both sides to keep the upper plane of the walking beam perpendicular to the centerline of the rail.

2. Repeat the above operation to install another walking beam. The diagonal error of the two walking beams is ± 1.5cm, and the center distance is 1cm.

Seventh, the connection between the gantry

Connect each product door frame to columns, beams, diagonal braces, and small beams as sticks, and place them in sequence according to the serial number.Bundle the upper beam of the door frame with steel wire ropes, and hang vertically between the two walking beams. Install the door frame to the walking beam in order, and then tighten all the connection screws of the door frame.

Eighth, installation of lifting cylinders and translation trolleys

When installing the lifting cylinder and translation trolley, pay attention to the lifting cylinder can be fastened to the cross beam on the mast by the number, and then the 90-degree plywood can be tightened with screws. Then connect the translation beam to the lifting cylinder with a locking pin.After this work is completed, the diagonal error of the four lifting cylinders is ± 1.5cm and the center distance is ± 1cm.

Tunnel formwork channel

Ninth, the installation of the upper longitudinal beam

Hang the upper longitudinal beam to the lifting cylinder according to the number, and connect it with the flange of the lifting cylinder with screws. After this work is completed, it is required to check the diagonal again, and after the center distance is qualified, place the hydraulic station in the designated place on the drawing. And tighten the bottom connecting bolts.

Tenth, the installation of the vault transverse plate

When lifting the main arch template, first check whether the lifting ears are welded firmly before lifting. Hang each template to the upper beam according to the serial number, and connect with the upper beam with bolts. Adjust the formwork joints and the wrong table, fasten all bolts, and complete the vault formwork installation in turn. (Note: The joints of the arch template are ± 1mm, and the staggered ± 0.5mm. All bolts must be tightened in the same direction, spring pads. Flat pads must be worn.

Eleventh, installation of side formwork

The side wall template is hoisted upright according to the number, the hinged ear hole of the vault template coincides with the axis of the hinged ear of the side template, penetrates the hinge pin, and locks with the lock pin. Note that it cannot be installed on one side at a time, and the two sides must be installed separately. A maximum of three side walls can be hung on one side, in order to maintain the upper vault balance, and then the hoisting is completed according to the serial number. It is required that after the installation of the side wall template is completed, the gap adjustment can be performed. It is required that the wrong platform cannot be greater than ± 0.5mm, and the side wall template is +0.00 below the waistline.

Twelfth, installation of trolley accessories

1. Install working platforms and escalators at both ends.

2. Connect and install side mold longitudinal joint, side mold cylinder and translation cylinder.

3. Connect the hydraulic pipeline, pay attention to the direction of the oil pipe, and it should be horizontal and vertical. When installing the operation valve, pay attention to the control sequence of the oil cylinder, and install from the two sides to the middle. After the oil pipe installation is completed, the inlet and return pipes can be tested and flushed with hydraulic oil. After completion, it can be connected with the oil cylinder to ensure that the oil circuit is unblocked.

4. Hang all mechanical support rod assemblies. Pay attention to the positive and negative wire buckle, which is convenient to use.

Thirteenth, inspection and confirmation

After the above work is completed as required, all the panel lifting ears can be cut off, and then polished, until it is qualified and meets the requirements. Then the trolley is adjusted to the lining state according to the requirements of the drawing, and then it is tested and improved until it is submitted to the construction party for inspection and passed, and is given a signature.

Fourteenth, the construction of formwork concrete lining

The construction time of the moulded concrete lining is arranged according to the construction procedures. In principle, the distance from the excavation surface is no more than 40 meters. In the shallow buried and broken zone of the cave entrance, appropriate points are placed for monitoring and measurement. The measurement items are the sinking of the vault and the surrounding convergence values, and the lining is guided based on this.

The concrete lining is poured by factory-made lining trolleys, concrete pumps, and concrete mixer trucks. A total of one concrete pump and one lining trolley are prepared for the tunnel, which are entered from the tunnel exit.

The formwork lining trolley adopted by the concrete lining is driven by external force and supported in place. The main body is a truss type. When designing the trolley, ensure that its abdominal cavity can pass through the transport machinery. The trolley is 9.1 meters long and the length of each pouring is 9 meters. Before pouring the concrete, various inspection records should be made according to regulations to remove debris on the formwork and rebar.砼 Special persons shall be set up to inspect the state of the formwork, plugs, waterproof plates, hoses, water stop and reserved caves during the pouring construction. The pouring concrete is poured from bottom to top, and the uniformity of the load on the formwork trolley is paid attention to. The pouring height of the concrete on one side must not exceed 1 meter on the other side.

The end plug of the formwork trolley door adopts a rubber injection plate to make the surface smooth and beautiful. The block plug in the hole is assembled with 4 forms. The trolley side wall formwork is provided with 2 rows of windows, and the vault is provided with a row of windows for pumps and vibrations. The windows are closed as the concrete is poured, and when the concrete is poured into the vault, the top windows are closed from both sides to the middle, and finally A hole is left in the middle form of the vault, and the conveying pipe is pushed into the concrete until the end plug emerges from the concrete to ensure that the concrete fills the vault.