Technological Innovation, Wisdom Leads To The Future|Five New Equipment Intelligent Informatisation Pouring & Lining Trolley Newly Upgraded

In order to solve the construction quality problems of traditional lining trolleys and avoid concrete segregation, insufficient compactness, vault hollowing, concrete cracking, falling blocks, pockmarking, honeycomb and other phenomena caused by problems such as trolley runout, leakage of slurry, insufficient vibration, poor lapping, vault overpressure and other problems in the lining pouring process, in April 2017, Uniroc responded to the market demand and developed the first automatic pouring lining trolley in China.

After continuous technological upgrading, Uniroc launched a new generation of intelligent and informative pouring lining trolley in January 2024, which realises tunnel lining construction visualisation, data, intelligence and informatisation, and makes the construction easier, the supervision simpler and the quality more reliable.

I. Structural characteristics

Intelligent informatisation pouring lining trolley breaks through the force principle of traditional trolley structure, with short transmission routes and fewer nodes, so that deformation and mould running are not easy to occur in the pouring process; the formwork, gantry, bracket, accessories, hydraulic, electrical and other systems adopt standardised and modularised design; all the working windows and channel openings on the panel of the trolley adopt laser undercutting, with high cutting precision and good sealing effect;The support rods are reduced by half compared with the traditional trolley, which is simple to operate, and can quickly set up and take off the mould, effectively reducing the time for mould collection and setting up; the space at the top, both sides and bottom of the trolley is very large, which improves the working environment, enhances the ventilation cross-sectional area, and facilitates the movement of engineering vehicles; the trolley as a whole adopts a user-friendly design, and the front, rear and vertical ends of the trolley are equipped with a ladder platform and a guardrail, which effectively improves the safety of on-site construction and the civilised level of construction.

2、Layered pouring

The new generation of BL300 layered placing system, with fully upgraded technology, realises continuous and spacious platform operation, and the working space is greatly improved; only 1 pipe is fed into the material on one side, and the total number of bends of conveying pipeline is greatly reduced, which greatly reduces the risk of blocking the pipeline, and the pipeline is more conveniently cleaned, and the whole pouring process only needs to be cleaned for 3 times. From the arch line to the top of the arch, full-coverage pouring with pressure greatly improves the compactness of concrete pouring.

3、 Vibration system

The trolley is equipped with inserted and attached high-frequency automatic vibrating system, and the operator can control the continuous vibrating time, interval time and vibration times through PLC programme. The vibrating system can be designed as single-action or group linkage according to the demand, and can be operated by unlimited remote control as an option; the inserted vibrating system of the arch section can fully vibrate the deep part of the concrete of the arch section through the reciprocating motion of the inserted high-frequency vibrator, so as to realise the full coverage of vibration in the direction of the ring direction, longitudinal direction and the thickness direction, and to effectively improve the concrete strength and denseness.

4、Self-laying track system

The trolley is equipped with special rails and rail lifting and carrying devices, cancelling the sleepers used for walking the traditional trolley. The track does not need to be manually carried and can be laid independently, which effectively reduces the labour intensity of workers and the number of operators.

5、Visualised blocking device

The blocking device is a visual polymer expansion and contraction structure, adopting lightweight and standardised design, with quick-dismantling structure between the upper and lower blocking devices and between the lower blocking device and the main template, adjustable expansion and contraction of the upper blocking device, and replacing the wooden moulds with rubber blocks to completely abolish the blocking of wooden moulds. Strong adaptability, easy disassembly and installation, greatly reducing labour intensity and improving work efficiency; the template can be reused, reducing construction costs; adjacent parts are in close contact with each other, with good sealing, avoiding slurry leakage in construction joints.

6、Soft-lap technology

The trolley adopts soft-lap mould technology to prevent the process of setting up the mould from cracking the poured concrete at the location of ring and longitudinal construction joints; and to form a closed space at the lining location to prevent segregation caused by leakage of slurry, aggregate splitting and other concrete quality problems.

7、Periscope pouring device

The trolley is equipped with periscope pouring device, which has the functions of telescopic and rotary, remote control, and convenient operation. When pouring at the top of the arch, the telescopic periscope pouring device reaches the top surface of the formwork and rotates while pouring to control the direction and flow of pouring, which changes the problem of the traditional way of pouring at the top of the arch that can't control the direction and flow of pouring, greatly reduces the probability of hollowing out of the arch, and improves the quality of the concrete pouring.

8、Digital maintenance system with mould

The trolley is equipped with digital maintenance system with mould, after the trolley is demoulded, the system uses the gap between the template and the lining surface after the trolley is demoulded to block the four edges to form a sealed space, and set up 16 water mist outlets and 16 steam outlets on the double layer. Intelligent detection of temperature and humidity, water mist device and steam device control the whole operation of the curing temperature and humidity can be controlled, to achieve immediate maintenance after demoulding, to solve the technical problems of the lack of initial maintenance of the second lining, to reduce the risk of concrete cracking.

9、 Informatisation Monitoring System

Intelligent informatised pouring and lining trolley is equipped with informatised monitoring system, which not only has the functions of anti-void warning for vault, anti-overpressure warning for vault, video monitoring, report generation, etc., but also allows the user to preset the pouring scheme according to the construction experience and the on-site construction situation through the interactive and editable interface, and to modify the process and parameter curing data of the pouring and vibration modules in real time, so that standardised construction can be achieved ultimately. Meanwhile, through the information management system of ‘Five New e-Managers’ tunnel intelligent equipment, users can monitor in real time the sequence and position of the trolley pouring into the silo, the volume of the pouring square, the flow rate of the corresponding pouring port, the temperature of the concrete entering the mould, the ambient temperature and humidity of the lining construction position, the fullness of the arch and the pressure of the arch in the process of pouring, etc., and all the monitoring information can be uploaded and stored, so that the process can be controlled and stored, and the process can be controlled and stored, All monitoring information can be uploaded and stored to achieve process control and traceability.

On the basis of the success of the five new automatic pouring and lining trolley, the new generation of intelligent information-based pouring and lining trolley has achieved another major breakthrough in the tunnel pouring and lining process. At present, this product has been widely used in major railway and highway projects and has won the praise of users, making tunnel construction safer, more economical and more efficient!