JP7744261B2 - Deck replacement method and boom-reversal deck erection machine - Google Patents

Description

This invention relates to a deck replacement method and boom-reversing deck erection machine that allows for the easy and continuous removal of existing decks without delays due to reinforcement during the erection of new decks or due to the casting of cast-in-place sections of the deck.

When replacing bridge decks, there are width restrictions when removing the existing deck from the bridge surface and erecting a new deck. This means that machines such as cranes that can expand their working area in the width direction when rotating cannot be used, so the work is often carried out using erection machines specifically designed for deck replacement.

As an example of an erection machine dedicated to this type of deck replacement, a portal deck erection machine 300 with four pillars 301 is known, as shown in Figure 14. This portal deck erection machine 300 installs the pillars 301 on the new deck 102 and the existing deck 104 on both sides of the deck replacement area E1. The upper end of the pillar 301 has a bridge section that extends in the bridge axis direction and guides the suspension section 302 in the bridge axis direction. The suspension section 302 is connected to the bridge section via a swivel mechanism 303. To remove the existing deck 101, the existing deck 101 is lifted using the lifting part 302 (A101), moved to the intermediate position P100 toward the existing deck 104 (A102), rotated 90 degrees by the swivel mechanism 303 at the intermediate position P100 (A103), and then moved further toward the existing deck 104 (A104), after which it is suspended from the loading platform of the waiting trailer 202 (A105). The trailer 202 loaded with the existing deck 101 is then transported by the tractor 201 in the removal direction A106. Note that the installation of the new deck is performed in the reverse order of the procedure for removing the existing deck 101.

Japanese Patent Application Laid-Open No. 2018-104972 Japanese Patent Application Laid-Open No. 2017-223080

Conventional portal-type deck erection machines install columns on the new and existing decks, which are on either side of the deck replacement area. Therefore, when the deck is lifted, the reaction force of the erection machine acts on the new deck. Therefore, mortar is poured under the new deck to transmit the reaction force of the erection machine to the steel girders. In this case, because the new deck is fixed in place by pouring non-shrinkage mortar, work cannot proceed to the next deck replacement cycle until the non-shrinkage mortar has developed its initial strength. Therefore, process management must take into account the hardening time of the non-shrinkage mortar.

On the other hand, when removing the existing deck slab in the cast-in-place deck section, the portal deck erection machine installs columns on both sides of the deck replacement area, so after removing the deck, it is necessary to wait until the deck slab in the cast-in-place deck section has been poured and its initial strength has been achieved, delaying the work process. To prevent this process delay, it is possible to pass through the cast-in-place deck section and replace only the precast deck slab, and then use a separate construction machine to remove the existing deck slab in the cast-in-place deck section, but this would incur additional construction costs.

The present invention was made in consideration of the above, and aims to provide a deck replacement method and boom-reversal deck erection machine that can easily and continuously remove existing decks without the need for process management that takes into account the development of mortar strength when erecting new decks.

In order to solve the above-mentioned problems and achieve the objectives, the present invention provides a deck replacement method in a deck replacement area in which existing decks are sequentially removed and new decks are sequentially erected. The method comprises a boom-reversal deck erection machine that is positioned on the existing deck side outside the deck replacement area, is arranged in parallel in the bridge width direction with a gap that exceeds at least the deck width, and has booms that are reversible and extendable synchronously in the bridge axis direction, the ends of the booms are connected by a boom top beam, and is suspended from the boom top beam and has a lifting section with a swivel mechanism. When removing the existing deck in the deck replacement area, the boom is directed toward the deck replacement area, and the existing deck to be removed is suspended from the lifting section. The existing deck is then rotated 90 degrees by the rotating mechanism so that its longitudinal direction is aligned with the bridge axis. In this state, the boom is reversed and the suspended existing deck is moved to a loading/unloading area outside the deck replacement area. When erecting the new deck in the deck replacement area, the boom is directed toward the loading/unloading area and the new deck, with its longitudinal direction aligned with the bridge axis, is hung from the hanging section. The boom is then reversed toward the deck replacement area and the suspended new deck is moved to the deck replacement area. The suspended new deck is then rotated 90 degrees by the rotating mechanism so that its longitudinal direction is aligned with the bridge width direction, and the new deck is erected in this state.

Furthermore, in the above invention, the present invention is characterized in that a trailer is placed in the loading/unloading area to transport the existing deck slab or to load the new deck slab.

In the above invention, the present invention is also characterized in that the booms extend and retract synchronously to adjust the position of the hanging part.

The present invention also provides a boom-reversing deck erection machine used for deck replacement in a deck replacement area, where existing decks are sequentially removed and new decks are sequentially erected. The machine has booms that are positioned on the side of the existing deck outside the deck replacement area, are arranged in parallel in the width direction with a gap that at least exceeds the deck width, and are reversible and extendable in sync in the bridge axis direction, and the ends of the booms are connected by a boom top beam and have a hanging section that is suspended from the boom top beam and has a swivel mechanism. When removing the existing deck in the deck replacement area, the boom is directed toward the deck replacement area and the existing deck to be removed is hung from the hanging section. The existing deck is then rotated 90 degrees by the swivel mechanism so that the longitudinal direction of the existing deck is aligned in the bridge axis direction, and in this state the boom is reversed to move the suspended existing deck to a loading/unloading area outside the deck replacement area. When erecting a new deck in the deck replacement area, the boom is directed toward the carry-in/carry-out area, and the new deck with its longitudinal direction oriented in the bridge axis direction is hung from the hanging section. The boom is then inverted toward the deck replacement area, and the suspended new deck is moved to the deck replacement area. The suspended new deck is then rotated 90 degrees by the rotation mechanism so that the longitudinal direction of the new deck is oriented in the width direction, and the new deck is erected in this state.

Furthermore, in the above invention, the present invention is characterized in that a loading/unloading area is formed on the existing deck side outside the deck replacement area, where a trailer is positioned to transport the existing deck or to bring in the new deck.

In the above invention, the present invention is also characterized in that the booms extend and retract synchronously to adjust the position of the hanging part.

According to this invention, there is no need for process management that takes into account the development of mortar strength during the erection of new deck slabs, and existing deck slabs can be easily and continuously removed.

FIG. 1 is a schematic side view illustrating the removal work of an existing deck using a boom reversal type deck erection machine according to this embodiment. FIG. 2 is a schematic plan view of the boom reversal type deck erection machine shown in FIG. FIG. 3 is a schematic front view of the boom reversal type deck erection machine shown in FIG. 1. FIG. 4 is a perspective view of the boom reversing type deck erection machine shown in FIG. 1. FIG. 5 is an explanatory diagram (part 1) illustrating the deck replacement work process using the boom reversal type deck erection machine shown in FIG. 1. FIG. 6 is an explanatory diagram (part 2) illustrating the deck replacement work process using the boom reversal type deck erection machine shown in FIG. 1. FIG. 7 is an explanatory diagram (part 3) illustrating the deck replacement work process using the boom reversal type deck erection machine shown in FIG. 1. FIG. 8 is an explanatory diagram (part 4) illustrating the deck replacement work process using the boom reversal type deck erection machine shown in FIG. 1. FIG. 9 is an explanatory diagram (part 5) illustrating the deck replacement work process using the boom reversal type deck erection machine shown in FIG. 1. FIG. 10 is a diagram showing a state in which the boom reversal type deck erection machine is being transported by a truck. FIG. 11 is a diagram showing a state in which the connecting beam is widened on the bed of a truck. FIG. 12 is a diagram showing the state in which the boom reversal type deck erection machine is lowered onto the existing deck. FIG. 13 is a diagram showing a state in which the boom reversal type deck erection machine is maintained horizontally using a cylinder jack. FIG. 14 is a diagram showing an example of a conventional portal deck erection machine.

The following describes an embodiment of the present invention with reference to the accompanying drawings. Figure 1 is a schematic side view illustrating the removal of an existing deck using a boom reversal type deck erection machine 1 according to this embodiment. Figure 2 is a schematic plan view of the boom reversal type deck erection machine 1 shown in Figure 1. Figure 3 is a schematic front view of the boom reversal type deck erection machine 1 shown in Figure 1. Figure 4 is a perspective view of the boom reversal type deck erection machine 1 shown in Figure 1. Figure 5 is an explanatory diagram illustrating the deck replacement work process using the boom reversal type deck erection machine 1 shown in Figure 1.

In Figures 1 to 4, the boom-reversing deck erection machine 1 is located at one end of the deck replacement area E1, where the existing deck slabs 101 are sequentially removed and new deck slabs 102 are sequentially installed, in the existing deck area E2 outside the deck replacement area E1. The boom-reversing deck erection machine 1 is positioned in the width direction (±X direction) at a distance that exceeds at least the deck width of the deck divided in the bridge axis direction (±Y direction), and has two telescopic booms 11 that can be reversed and extended in sync in the bridge axis direction (±Y direction). The telescopic booms 11 each rotate around axes C1 and C2 of the erection machine main body 2. The tips of each telescopic boom 11 are connected by a boom top beam 13. The telescopic booms 11 are rotated by boom folding cylinders 11a and extended by boom reversing cylinders 11b.

A hoisting unit 12 is suspended from the boom top beam 13. A width-direction movement mechanism 14 having a swivel mechanism 15 is connected to the boom top beam 13 for the hoisting unit 12, and a deck lifting device 17 is connected to the swivel mechanism 15 via a swivel lifting balance 16. The width-direction movement mechanism 14 fine-tunes the widthwise position of the deck when erecting or removing the deck. The swivel mechanism 15 rotates the deck around the vertical axis (Z-axis) when erecting or removing the deck. The deck lifting device 17 raises and lowers the suspended position of the deck. The width-direction movement mechanism 14, swivel mechanism 15, and deck lifting device 17 are driven by electric motors.

In the -Y direction of the construction machine main body 2, there is a main beam 2b that extends from each axis C1, C2 in the -Y direction and supports the telescopic boom 11. A counterweight is placed at the -Y end of the main beam 2b. The main beam 2b has tires 2a at its bottom, allowing the boom-reversal deck slab erection machine 1 to propel itself using a hydraulic motor. The boom-reversal deck slab erection machine 1 can also propel itself using rails, rather than tires 2a. The main beam 2b is connected by multiple connecting beams 3. A steel plate for the trailer 202 to travel on is installed on the connecting beams 3, allowing the trailer 202 to enter the loading/unloading area E via a slope. The construction machine main body 2 also has the function of maintaining the construction machine main body 2 level in response to longitudinal and transverse gradients, for example, using outriggers. The engine-driven hydraulic unit that drives and controls the hydraulic mechanisms of each section and the power generation unit that supplies power to the electric motor are externally located and connected to the construction machine main body 2 in the -Y direction.

When working to move to the next deck replacement area adjacent to the current deck replacement area E1 on the side of the current existing deck area E2, the boom reversal deck erection machine 1 moves in the -Y direction by self-propelled movement. At this time, the boom reversal deck erection machine 1 preferably self-propels with the telescopic boom 11 inverted in the -Y direction and folded. The trailer 202 is connected to the tractor 201 and towed. The boom reversal deck erection machine 1 may be controlled remotely, or the driver's seat may be located in a location that does not affect the movement work. A new deck 103 that has already been installed by replacement is placed in the installed area E3 adjacent to the deck replacement area E1 in the -Y direction.

<Deck replacement work process>
Next, the deck replacement work process will be described with reference to Figures 5 to 9. First, as shown in Figure 5, the boom-reversing deck erection machine 1 is deployed and positioned on the deck replacement area E1 side of the existing deck area E2. Then, as shown in Figure 6, the trailer 202 is moved into the loading/unloading area E. After that, as shown in Figure 7, the peeled existing deck 101 is hung from the hoisting section 12, and the telescopic boom 11 is inverted and extended to carry it to the bed of the trailer 202. At this time, after being hung, the existing deck 101 is rotated 90 degrees by the swivel mechanism 15 so that the longitudinal direction of the existing deck 101 is oriented in the bridge axis direction. Then, the rotated existing deck 101 is maintained in its current position and placed between the telescopic booms 11 on the bed of the trailer 202. Once the two existing deck slabs 101 are loaded onto the trailer 202, the trailer 202 leaves the loading/unloading area E and is transported.

The telescopic boom 11 is extended and retracted as needed. For example, this is done when the existing deck slab 101 is located far from the boom reversal deck erection machine 1, or when the loading platform of the trailer 202 on which the existing deck slab 101 is to be placed is far away. The tip position of the telescopic boom 11 is adjusted and retracted so that it can cover lifting in the deck slab replacement area E1 as well as in the loading and unloading area E. In the loading and unloading area E, two decks may be loaded on the trailer 202, and the working radius of the telescopic boom 11 is adjusted in advance to a range that allows two decks to be loaded.

Specifically, as shown in Figure 1, if the position of the existing deck slab 101 in the loading/unloading area E is close to the erection machine main body 2, the boom tip moves along trajectory L1 and over the existing deck slab 101 as indicated by arrow A1. Also, if the position of the existing deck slab 101 in the loading/unloading area E is far from the existing deck slab area E2, the boom tip moves along trajectories L1 and L2 and over the existing deck slab 101 as indicated by arrow A2. Furthermore, if the existing deck slab 101 in the deck replacement area E1 is far from the erection machine main body 2, the boom tip extends in the +Y direction along trajectory L3.

Then, the new deck 102 is erected in the deck replacement area E1. First, as shown in Figure 8, a trailer 203 carrying the new deck 102 enters the loading/unloading area E. Then, the new deck 102 is moved from the trailer 203 to the deck replacement area E1 in the reverse order of the removal process of the existing deck 101. Specifically, the telescopic boom 11 is directed toward the loading/unloading area E, and the new deck slab 102, with its longitudinal direction oriented in the bridge axis direction, is hung from the suspender 12. The telescopic boom 11 is then inverted toward the deck replacement area E1, and the suspended new deck slab 102 is moved to the deck replacement area E1. The suspended new deck slab 102 is then rotated 90 degrees by the rotating mechanism 15 so that its longitudinal direction is oriented in the width direction, and in this state the new deck slab 102 is erected on the main girder 100. When the erection of the two new deck slabs 102 loaded on the trailer 203 is complete, the trailer 203 exits the loading/unloading area E.

Then, as shown in Figure 9, the boom reversal type deck erection machine 1, with the telescopic boom 11 inverted and folded, moves under its own power from the next deck replacement area E1' to the existing deck area E2. Then, as shown in Figure 5, the boom reversal type deck erection machine 1 is unfolded, and the above work procedure is repeated.

<Deployment of boom-reversing deck erection machines>
Next, an overview of the deployment of the boom reversal type deck erection machine 1 will be described with reference to Figures 10 to 13. As shown in Figure 10, the boom reversal type deck erection machine 1 is transported on a trailer 204 with multiple connecting beams 3 folded between the main beams 2b. At this time, the spacing between the main beams 2b is equal to or less than the width of the trailer 204 bed. After the trailer 204 enters the loading/unloading area E, as shown in Figure 11, the connecting beams 3 are widened in the width direction (±X direction) by the widening cylinders 20. Accordingly, the main beams 2b and the telescopic boom 11 connected thereto also widen in the width direction. As a result, the main beams 2b and the telescopic boom 11 move outside the bed beyond the width of the trailer 204 bed. Here, by extending the cylinder jacks 21 serving as outriggers arranged at the four corners vertically downward, a gap is created between the boom reversal type deck erection machine 1 and the bed of the trailer 204. In this state, the trailer 204 can move in the −X direction, and the trailer 204 leaves the loading/unloading area E.

After the trailer 204 has withdrawn, as shown in Figure 12, the cylinder jack 21 is extended vertically upward to place the boom-reversal deck erection machine 1 on the existing deck 101. Then, steel plates 311 are placed on the connecting beam 3, and slopes 312 are placed at the front and rear (±Y direction) ends of the connecting beam 3 to facilitate the trailer 205 carrying the peeled existing deck 101 entering and exiting the loading/unloading area E. At this time, the counterweight 30 is positioned behind each main beam 2b of the erection machine body 2 (-Y direction).

As shown in Figure 13, the existing deck 101 has an inclined surface S, such as a longitudinal gradient or a transverse gradient, so the cylinder jack 21 is adjusted as an outrigger to maintain the horizontal plane H of the boom-reversal deck erection machine 1. This allows for stable movement of the existing deck 101 and the new deck 102.

In this embodiment, the boom-reversing deck erection machine 1 is positioned on one side of the deck replacement area E1, i.e., on the side of the existing deck area E2, and the existing deck 101 and new deck 102 are moved by reversing the telescopic boom 11. This eliminates the need for process management that takes into account the development of mortar strength when erecting the new deck 102, and eliminates process delays due to deck casting in the cast-in-place section of the deck. This allows the existing deck 101 to be easily removed in succession, and the new deck 102 to be erected in succession.

In this embodiment, the boom length allows for four deck slabs to be replaced per day, doubling work efficiency compared to the conventional rate of three deck slabs per day. Furthermore, the boom-reversal deck erection machine 1 has a low center of gravity, providing high stability when moving deck slabs.

Furthermore, the components illustrated in the above embodiments are merely functional schematics and do not necessarily have to be physically configured as shown. In other words, the distribution and integration of each device and component is not limited to that shown, and all or part of them can be functionally or physically distributed and integrated in any unit depending on various usage conditions, etc.

DESCRIPTION OF SYMBOLS 1 Boom-reversing deck erection machine 2 Erection machine body 2a Tire 2b Main beam 3 Connecting beam 11 Telescopic boom 11a Boom folding cylinder 11b Boom reversing cylinder 12 Lifting section 13 Boom top beam 14 Width direction movement mechanism 15 Swivel mechanism 16 Swivel lifting balance 17 Deck slab lifting device 20 Widening cylinder 21 Cylinder jack 30 Counterweight 100 Main girder 101 Existing deck 102 New deck slab 103 Erected new deck slab 201 Tractor 202, 203, 204, 205 Trailer 311 Iron plate 312 Slope A1, A2 Arrows E Loading/unloading area E1 Deck slab replacement area E2 Existing deck area E3 Installed area H Horizontal plane L1 to L3 Track S Inclined surface

Claims (6)

A slab replacement method in a slab replacement area in which existing slabs are sequentially removed and new slabs are sequentially erected,
A boom-reversing deck erection machine is provided, which is arranged on the existing deck side outside the deck replacement area, has booms arranged in parallel in the width direction with an interval that exceeds at least the deck width, and is reversible and extendable synchronously in the bridge axis direction, and the tips of the booms are connected by a boom top beam, and has a hanging part that is suspended from the boom top beam and has a swivel mechanism,
When removing the existing deck in the deck replacement area, the boom is directed toward the deck replacement area, and the existing deck to be removed is hung from the hanging section. The existing deck is then rotated 90 degrees by the rotating mechanism so that the longitudinal direction of the existing deck is oriented in the direction of the bridge axis. In this state, the boom is reversed, and the suspended existing deck is moved to a loading/unloading area outside the deck replacement area.
When erecting a new deck in the deck replacement area, the boom is directed toward the loading/unloading area, and the new deck with its longitudinal direction facing the bridge axis direction is hung from the hanging section, then the boom is flipped toward the deck replacement area and the hung new deck is moved to the deck replacement area, and then the hung new deck is rotated 90 degrees by the rotating mechanism so that the longitudinal direction of the new deck is facing the width direction, and the new deck is erected in this state.This deck replacement method is characterized by the following. The deck replacement method described in claim 1, characterized in that a trailer for transporting the existing deck or for transporting the new deck is placed in the loading/unloading area. A deck replacement method as described in claim 1 or 2, characterized in that the booms extend and retract synchronously to adjust the position of the hanging part. A boom-reversing deck erection machine used for deck replacement in a deck replacement area in which existing decks are sequentially removed and new decks are sequentially erected,
The bridge has booms that are arranged on the existing deck side outside the deck replacement area, arranged in parallel in the width direction with an interval that exceeds at least the deck width, and are reversible and extendable in synchronization with the bridge axis direction, the tips of the booms are connected by a boom top beam, and a hanging part that is suspended from the boom top beam and has a swivel mechanism,
When removing the existing deck in the deck replacement area, the boom is directed toward the deck replacement area, and the existing deck to be removed is hung from the hanging section. The existing deck is then rotated 90 degrees by the rotating mechanism so that the longitudinal direction of the existing deck is oriented in the direction of the bridge axis. In this state, the boom is reversed, and the suspended existing deck is moved to a loading/unloading area outside the deck replacement area.
When erecting a new deck in the deck replacement area, the boom is directed toward the loading/unloading area, and the new deck with its longitudinal direction oriented in the bridge axis direction is hung from the hanging section, and then the boom is inverted toward the deck replacement area to move the hung new deck to the deck replacement area, and then the hung new deck is rotated 90 degrees by the rotating mechanism so that the longitudinal direction of the new deck is oriented in the width direction, and the new deck is erected in this state.This is a boom-reversal type deck erection machine. A boom-reversing deck erection machine as described in claim 4, characterized in that a loading/unloading area is formed on the existing deck side outside the deck replacement area, where a trailer is positioned to transport the existing deck or to load the new deck. A boom-reversing deck erection machine as described in claim 4 or 5, characterized in that the booms extend and retract synchronously to adjust the position of the hanging part.