In order to improve the quality of tunnel construction and implement the requirements for project management standardization, the design and acceptance criteria of the formwork trolleys are unified. It is required that the tunnel lining formwork trolley adopts a unified structural form and processing technical standard, and is accepted and accepted according to the same acceptance criteria. The processing technical standards and acceptance criteria of the formwork trolley are issued, and the relevant departments are requested to provide the template table according to the following requirements. Car processing plan:

First, the technical standards for tunnel lining trolley processing:

1. The length is designed according to 12m.

2. The profile of the lining section is designed to be 50mm larger according to the contour of the cross section of the attached tunnel.

3. The surface adopts the national standard 10mm cold rolled sheet.

4. The clearance in the gantry should ensure the safe passage of vehicles and personnel in the cave. It is necessary to consider the traversing form of the wind and water pipelines inside the cave, and consider placing them on the lower side of the trolley in parallel. The ventilation pipe is considered to have a diameter of 1.2 m, and a space of 1.4 m is required to be placed and placed on the upper side of the gantry (not placed in the middle).

5. The trolley lifting cylinder stroke, side mold cylinder stroke and traverse cylinder stroke are designed to be 300mm.

6. The working windows are staggered according to the type of characters, the size is 500 mm×500 mm, the layer height is not more than 1800 mm; the vault is arranged with two grouting ports with the same diameter as the concrete pump, and the joints and seals are provided.

7. Lay 200mm × 200mm sleepers on the top of the inner rail at 1060mm and adopt P43 rail design.

8. Lower longitudinal beam: Two I60 I-beams are used to form a group of welded parts; the gantry column is made of I36C I-beam; the upper longitudinal and transverse beams and the middle longitudinal and transverse beams are assembled into two sets of welded parts by two I30a I-beams; The scissors support I20a I-beam. (I60 600 × 190; I36C 360 × 140; I30a 300 × 145; I20a 220 × 110. Data: height × leg width, unit mm).

9. If the material of the above-mentioned 8th trolley is replaced by other materials, the substitute material shall not be lower than the standard in Article 8; the gantry structure, support system and formwork of the formwork trolley shall be guaranteed to meet various construction loads. It has sufficient strength and rigidity to be deformed within the requirements of the Bata Railway and national regulations.

10. The template joints should be tight and not leaking, the surface flatness is not more than 3mm, the seam is not more than 1mm.

11. The width of the panel is not less than 1500mm, and the walking speed of the trolley is about 6m/min.

12. The lining trolley should be provided with sufficient load-bearing screw support and radial formwork screw support.

13. Using full hydraulic positioning, hydraulic system working pressure 16Mpa.

14. The surface is ground and oiled on the basis of the original steel plate; except for the surface of the template, the non-machined surface of all parts is coated with a reddish topcoat.

15. The demoulding method is considered by each manufacturer.

16. The vertical gantry is longitudinally arranged at a spacing of not less than 2 meters.

17. The plug template should be considered in the design and designed separately.

18. The lower part of the outer formwork is hinged at a height of 50 cm, and the lower 50 cm high part can be rotated to the inner side, and the height of the lower edge is not less than 30 cm.

19. The design comes with a walking system.

Second, tunnel lining trolley acceptance criteria

1, the main body part

(1) The structural parts of the skeleton structure are smooth and beautiful, without bending, bending and torsion deformation, the weld placement is reasonable, the thickness of the weld is up to standard, and there is no welding and other welding defects.

(2) After assembly, the bolt holes are basically free of misalignment.

(3) After assembly, the diagonal error of the main door frame is not more than ±5mm, and the verticality of each gantry is not more than 5mm.

2, hydraulic operating system

(1) Each valve and cylinder move freely, and the effective stroke of the cylinder is reasonable.

(2) The piping of the system is arranged reasonably, and there is no oil leakage in each joint.

(3) The top mold, the side mold (or the bottom mold) are demoulded, the position is flexible, and there is no card collision.

3, walking system

(1) The walking system moves freely, without jitter, slipping and the like.

(2) There is no oil leakage in the walking gearbox, and the chain sag is moderate.

4, the template

(1) There is no shortage of welding and desoldering of the single template. The arch plate has no distortion, and the rib plate has no curved panel and has no defects such as rust, convex and concave.

Serial number	Project	Standard	Acceptance method
1	Actual contour and design contour surface arbitrary point normal error	≤3mm	Ruler
2	The working window panel and the surface of the template should be in the same arc: wrong platform, gap	≤1.5mm	2m by foot and feeler
3	Diagonal error	≤3mm	Ruler
4	Length error	±2mm	Ruler
5	Width error	±2mm	Ruler
6	Contour surface (arc surface) flatness	≤3mm/2m	2m by foot and feeler
7	Hinged hole position error	≤0.5mm	Ruler
8	Hinged hole center line link and template center line perpendicularity error	≤1mm	Ruler
9	Web and panel perpendicularity	1.5mm/300mm	Ruler

(2) After the template is assembled, the anti-rust paint is sprayed, and the surface treatment is polished before spraying, and the surface of the template is smooth, free from irregularities, no welding slag, burrs, and flash. The template storage, transportation and hoisting are equipped with anti-change measures.

Serial number	Project	Standard	Acceptance method
1	Contour radius	±3mm	Ruler
2	Template flatness	3mm/2mm	2m by foot and feeler
3	Template wrong	≤2mm	2m by foot and feeler
4	Template gap	≤1.5mm	2m by foot and feeler
5	Surface roughness	Polishing	2m by foot and feeler
6	Longitudinal straightness error of the outer contour surface of the template trolley	≤2mm	2m by foot and feeler
7	From the template vertices, divided by the height of 2m, the chord length and design error	≤ ± 2mm	Ruler
8	Front and rear end contour error of template trolley	≤3mm	Ruler

(3) Installation tolerance and inspection method for tunnel lining trolley

Serial number	Project	Standard	Acceptance method
1	Side wall corner	±10mm	Ruler
2	Arch line	±2mm	Ruler
3	Dome	±2mm	Level measurement
4	Template surface flatness	4mm	2m by foot and feeler
5	Adjacent casting section surface height difference	±4mm	Ruler

5, the work window

(1) The clearance between the hinge pin and the positioning pin is not more than 0.5mm.

(2) The unevenness of the surface of the working window and the surface of the template, that is, the misalignment with the surface of the template is not more than 1 mm.

(3) The gap between the perimeter of the work window panel and the formwork panel is no more than 1mm.

(4) Each work window is opened and closed freely.

6, support system

(1) The bending of each screw can not be greater than 2mm.

(2) The screw is flexible and the effective length of the thread is reasonable.

(3) The overall support system of the trolley is reasonably arranged and there is no weak support zone.

Tunnel lining trolleys will play a vital role in real life, especially in the use of industry will be able to play their biggest role, of course, often in the process of actual equipment processing, can not be separated from such A product that how to maintain it when it is actually used is something that many people want to know.

1) The tunnel lining trolley must be operated continuously for 15 working days during the maintenance process, and the hydraulic oil inside should be replaced after the cycle.

2) Every work cycle should be buttered to the top of the screw, and for the gantry or the concrete on the stencil and related stencils, be sure to pay attention to effective cleaning.

3) Each mold cycle must be coated with more release agent.

4) If concrete tunneling is to be carried out in a tunnel lining trolley, more piston rods must be covered on top to prevent concrete from falling on the piston rod surface.

5) After each time the tunnel lining trolley is demoulded, the bolts of each component should be effectively checked to see if they are loose. If there is looseness, tighten it. If it is not loose, then Be sure to better prevent the surface from appearing staggered.

Tunnel lining trolley daily use precautions

1. If you want to use the tunnel lining trolley, you must find the relevant operation manual to carry out effective installation and installation before use. All the processes need to check whether each component has a firm link one by one. It depends on their actual installation. In the case, after installation, you must also try again, to see if the rotation of the entire vehicle is flexible. Of course, when the installation is actually carried out, there will be various installation methods.

2. Nowadays, in the actual installation process of the tunnel lining trolley, the relevant position is basically to start the vertical mold. When the switch is started, the operator should cooperate with some other vehicles to install, so that the shape of the whole template can be reached. There is a construction requirement. When the entire formwork meets the construction requirements, the upper and lower templates will be precisely combined, and then the template of the entire tunnel lining trolley will be closed. After the two templates are assembled up and down, the concrete can be poured. By transporting the concrete to the relevant formwork trolley, basically, it is possible to perform better perfusion, and to maintain the balance of the trolley.

3. After the tunnel lining trolley is demoulded, the work can be completed after the strength of the inverted concrete reaches a certain operational requirement.

Tunnel lining trolley This kind of equipment will belong to a unique equipment in real life, and the whole equipment must be paid attention to when using it. It must be maintained and maintained by this professional. Otherwise, if it is true If you want to operate, you should also choose a professional person to operate. Only in this way can you bring better protection to prevent problems later.

The tunnel lining formwork is a special equipment that must be used in the secondary lining of the tunnel construction process, and is used for lining construction of the inner wall of the tunnel. There are mainly simple lining trolleys, full hydraulic automatic walking lining trolleys and grid-type lining trolleys; full hydraulic lining trolleys can be divided into side-arched arches, full-round needle-beams, bottom die-pins, full circles walk through and so on. Lifting slipforms, jacking slipforms and overturning are also commonly used in hydraulic tunnels and bridge construction.

First. Lining formwork structure

The lining trolley consists of three parts: the frame, the formwork and the hydraulic power system. By hydraulically installing the vertical mold and demolishing the mold, the full-section lining of the tunnel can be completed at one time.

1. Trolley frame

It mainly includes gantry longitudinal beams, beams, columns, diagonal braces, side links, top links and walking parts. In the case of meeting the requirements of strength and rigidity, the steel design is adopted to ensure the structure is reasonable and the processing is simple and rapid. The connection of each component is connected by bolts and knots, which is easy to disassemble and easy to transport.

2. Template

The total length is 12m, divided into 8 segments, each segment is 1.5m long. Each segment consists of two side stencils and two top stencils in the circumferential direction. The entire trolley has a total of 32 templates. Each formwork consists of a panel, a skirt and a rib portion. This structure not only increases the overall rigidity of the formwork, but also increases the weight of the formwork, compared with the use of I-beam and channel steel.

The two top stencils are bolted together, which facilitates the installation, disassembly and adjustment of the stencil. The connection between the top template and the side template is hinged.

3. Support

The template support is divided into two parts: vertical lifting and lateral stretching. The vertical lifting adopts 6 vertical cylinders for lifting and lowering, and the lateral direction uses 6 lateral cylinders for expansion and contraction. The vertical cylinders are flanged and the side cylinders are earrings. After the template is in place, it is supported by a screw jack. This support method ensures that the formwork does not retract or deform when it is lining.

4. Template translation mechanism

There are 2 horizontal hydraulic cylinders on the top of the trolley frame to adjust the lateral position of the template.

5. Subsidiary decoration

The accessory frame includes 6 gantry jacks, 4 top bracket jacks, hydraulic pumping station, walking mounting, workbench, lighting circuit and so on. The hydraulic pump station is designed as a vertical closed structure. The hydraulic pump is placed in the fuel tank, and the multi-way reversing valve is placed above the fuel tank for easy operation and neat appearance.

Second. The main technical parameters

1. Template

The thickness of the panel is 12mm, the skirt is 12mm thick steel plate, and the rib is made of 70×50 angle steel. There are 4 attached vibrators and 4 concrete pouring spouts on the top of the template, and 24 working windows with a size of 500×450. The horizontal adjustment movement of the template is 150mm on the left and right.

2. Hydraulic power system

The pressure is 16 MPa and the flow rate is 14.5 L/min. The vertical cylinder has a cylinder diameter of 160 mm and a stroke of 400 mm with a hydraulic lock. The lateral cylinder has a cylinder diameter of 90 mm and a stroke of 730 mm with a hydraulic lock. Horizontal cylinder, cylinder diameter 90mm, stroke 300mm.

3. Trolley running

The trolley travels with motor drive, the running speed is 6.7m/min, and the traction is 39.13kN. 2 sets of Y112M-6 (2.2kW) motor, rated speed 940 rev / min; reducer model is DWPA147, speed ratio is 60:1; chain drive speed ratio is 2.932:1; wheel diameter is 400mm.

The above is the relevant introduction of the technical parameters of the tunnel lining formwork. At the same time, the above introduction is believed to make it easier and safer to use the tunnel lining formwork in the future.

Before the tunnel lining formwork is installed, it is necessary to level enough space at the hole. To lay the track, the track is best to face the hole so that the trolley can enter the hole. The crane is first hoisted with the gantry, and then the stencil is installed to finally install the hydraulic system and the power supply system. Since the trolleys are all connected by bolts and hinges, the installation is very convenient, just assemble them according to the drawings.

1. Select the installation location: According to the actual situation of the site, select the appropriate installation location, so that the trolley can enter the tunnel smoothly or enter the work surface.

(1) Installation outside the cave; large space, suitable for crane operation.

(2) Installation in the cave; the space is small, and the bolt lifting operation is required.

2. Level the site and lay the track. The site should be as flat and open as possible so that the installation can be carried out. The site is generally 20×30 meters, depending on the actual situation. (If the hole is installed, it needs to be 50 cm on the outside, 30 cm on both sides, and the length of the trolley is +3 meters long to facilitate the lifting operation. In order to successfully complete the installation task, it needs to be doubled at this position. The length of the trolley + 3 meters will be kept free of obstacles. When installing in the cave, it is necessary to set up bolts. The specific position is determined according to the technical department.

According to the trolley gauge requirements, the track is laid, the track requirements are straight, no obvious triangular pits, the joints are not wrong, the front and rear, left and right height difference <5mm, the center line is as close as possible to the tunnel center line, the error is <15mm, the track sleeper spacing Generally ≤ 0.5 m, and fastened with road spikes, the rail uses 38kg / m heavy rail.

3. Install the walking wheel frame assembly.

Use the lifting device (hand chain hoist or crane) to place the driving wheel frame and the driven wheel frame on the paved track and make temporary support. Adjust the distance between the front and rear wheel frames according to the center line of the bottom longitudinal beam, and use The principle of equal diagonality adjusts the correct orientation of the wheel carrier and flatten it.

4. Install the bottom stringer.

Hang the bottom stringer on the wheel frame that has been placed, and use bolts to add temporary support to check whether there is any change in the diagonal. If it is within the correct value, install the gantry.

5. Install the gantry.

Generally, the gantry monolithic assembly is assembled on the ground first. Then, one piece is hoisted at the opposite position of the bottom rail and temporarily fixed with bolts.

6. Install the lock beam, scissors support

In order to become an organic whole as soon as possible, the gantry is installed and the lock beam and the scissors support provided in each space are installed. Use the drop ball or eye view to adjust and correct. And tighten the bolts in time to form a complete skeleton.

7. Install various components such as jacking cylinders.

8. Lifting the lifting beam and installing the table beam.

First lift the table beam on the top lift cylinder, adjust the center distance and diagonal line, add temporary support, hoist the hanging beam on the table beam and fasten it with bolts.

9. Install the hanging beam column and top template.

When installing the top mold, it should start from the middle and extend to both ends. This can reduce the accumulated error. Install the first top mold in the middle. After checking the chord length and string height to meet the design standards, install the other top molds until the top mold is completed. Installation task.

10. For the stability of the trolley, all the diagonal braces and scissors support on the lifting beam are tightened at this time.

11. Install the side mold (using a crane or hand hoist).

After the top mold is inspected, the side mold can be installed. When installing the side mold, it should be installed symmetrically to prevent roll. If it is installed in the hole, the side mold should be transported into the hole before installation, and the template should be placed in the order. On the basis of the wall, in order to hoist. The side mold installation is adjusted, the surface is smooth, flat, the joints are free of faults, and the geometrical dimensions meet the design requirements, and the through beams can be installed.

12. Install the through beam and support system.

13. Install hydraulic and electrical systems.

If installed in a small hole, the walking electrical appliance must be installed before the trolley moves back and forth.

14. Installation accessories such as: railings, step ladders and work platforms, plugging plates and so on.

15. Check all fastening bolts.

16. No-load test, whether the electrical hydraulic system works normally.

17. Test whether the various actions of the trolley are flexible and accurate.

18. After passing the self-inspection, report to the user for acceptance.

19. If the acceptance is qualified, fill in the form, and both parties sign and put it into use.

Tunnel lining and initial support refer to the inner lining constructed with concrete and other materials under the condition that the tunnel has been initially supported to achieve reinforcement support, optimize the route drainage system, beautify the appearance, and facilitate the setting of communication. The role of lighting, monitoring and other facilities to meet the requirements of modern highway tunnel construction. Due to the construction conditions of the tunnel and the limitation of the construction environment, the construction of the two-line waterproof concrete in the tunnel is more difficult than the construction of the open-air concrete.

First, the main role

The function of the tunnel lining varies with the surrounding rock. For the stable surrounding rock of I, the deformation of the surrounding rock and the initial support is small and it tends to be stable soon, so the tunnel lining is basically not subjected to the surrounding rock pressure. The main function is waterproof and storage, and the flat lining surface is also conducive to ventilation and beauty. For the hard surrounding rock which is basically stable in II, although the deformation of the surrounding rock and the initial support is small, the surrounding rock pressure of the tunnel lining is not Large, but considering the long-term operation of the tunnel during the long-term operation of the anchor steel corrosion, the surrounding rock relaxation zone is gradually compacted, the initial support quality is unstable and other factors, so the tunnel lining is applied to increase the support lining safety; for III- V surrounding rock, due to the soft and broken rock mass, as well as rheological, expansion pressure, groundwater, etc., or due to shallow burial, bias and construction, etc., the self-stability of surrounding rock is very poor, only relying on initial support is not enough To suppress the development of surrounding rock deformation, the tunnel lining applied at this time will bear a large part of the late surrounding rock deformation pressure.

Second, the basic requirements

1. The degree of adhesion between the initial support and the tunnel lining will have an impact on the stress state of the composite lining. When there is a gap between the support and the lining, especially the concrete filled in the vault is not dense in real time, the surrounding rock pressure of the arch is saddle-shaped, that is, the vault is small and the arch is large, and even the outer side of the lining is pulled.

2. When the support and the lining are tightly bonded at the beginning, the radial force and the tangential force can be transmitted between the two layers, which can be checked according to the overall structure. When a waterproof layer is provided between the two layers, the combined structure is used to check and only the radial load is transmitted.

3. In order to prevent water leakage in the cave, the deformation of the tunnel lining should be controlled during design.

4. If there is a gap between the support and the lining, it should be backfilled and compacted.

Third, the calculation of tunnel lining

Due to the layered application of the composite lining, the time should be considered, and the calculation can be carried out according to the viscoelastic-plastic finite element method; the composite lining can also be approximated by the elastoplastic theory or the eigen curve method; On-site measurement data and model test results, as well as composite lining design adopted by internal and external data: For the external rock of tunnel lining with 30%-50% surrounding rock pressure for II-V surrounding rock, calculate by load-structure model . It should be pointed out that due to the insufficiency of the research on the mechanism of the tunnel lining, and the geological conditions of the surrounding rock are ever-changing, it is difficult to calculate the tunnel lining accurately. It is recommended to use simple and practical calculation methods. For weak surrounding rock with complex geological conditions, the tunnel lining calculation results of the above several methods should be compared to determine a reasonable and simple calculation method.

Fourth, the determination of the time for tunnel lining

For surrounding rock with better self-stability, tunnel lining should be applied after the surrounding rock and initial support deformation are basically stable, and the following conditions should be met:

1. The displacement rate around the tunnel has a significant slowdown trend.

2. The displacement speed of 1 m above the arch and the middle of the side wall is less than 0.1-0.2 mm/d, or the sinking speed of the dome is less than 0.07-0.15 mm/d.

3. The displacement value before applying the tunnel lining should reach 80%-90% of the total displacement value.

4. The surface cracks of the initial support no longer continue to develop.

5. When it is still difficult to meet the above conditions when taking certain measures, the tunnel lining may be applied in advance and should be strengthened.

For shorter tunnels and better self-stability of surrounding rock, tunnel lining can be applied after the entire tunnel is penetrated in order to reduce the interference between the various processes.

Fifth, measures to strengthen tunnel lining

For the complex geological conditions, the self-stability of the surrounding rock is poor, or in the case of shallow buried, biased, expansive surrounding rock, when the deformation of the surrounding rock and the initial support is not stable, it needs to be applied as a tunnel lining in advance. At this time, the tunnel lining is subjected to a large surrounding rock pressure, so the following measures are needed to strengthen the tunnel lining:

(1) Change the shape of the lining to adapt to the surrounding rock pressure, reduce the bending moment of the lining, and make the lining section basically under pressure.

(2) Improve the concrete marking, or use reinforced concrete, steel fiber concrete and other materials that can improve the bending strength.

(3) Applying the invert arch to form a closed structure for the lining to improve the overall rigidity of the structure and reduce the deformation of the surrounding rock.

(4) Measures such as advanced support and grouting to strengthen surrounding rock to increase the strength of the rock mass and improve the overall stability of the surrounding rock.