초록 ▼

∘ 이 연구에서는 “기술자립 및 국제 경쟁력 확보를 위한 공기단축형 콘크리트 고주탑 가설 장비 및 공법 개발”을 목표로 “변단면 고주탑을 위한 슬립폼 장비 및 공법”, “GPS를 이용한 400m 이상 고주탑 시공 정밀도 관리”, “변단면 대응이 가능한 경량 슬립폼 모듈” 등 3개 핵심기술을 개발함.

∘ 1단계에서는 핵심기술에 대한 원천기술을 독자적으로 도출하고 그 상세를 개발하였음.

구체적으로는 BIM 기반 3D 설계 및 디지털 가상 시공을 적용하여 변단면 슬립폼시스템을 개발하여 제작오차 및 시공 시 시행착

∘ 이 연구에서는 “기술자립 및 국제 경쟁력 확보를 위한 공기단축형 콘크리트 고주탑 가설 장비 및 공법 개발”을 목표로 “변단면 고주탑을 위한 슬립폼 장비 및 공법”, “GPS를 이용한 400m 이상 고주탑 시공 정밀도 관리”, “변단면 대응이 가능한 경량 슬립폼 모듈” 등 3개 핵심기술을 개발함.

∘ 1단계에서는 핵심기술에 대한 원천기술을 독자적으로 도출하고 그 상세를 개발하였음.

구체적으로는 BIM 기반 3D 설계 및 디지털 가상 시공을 적용하여 변단면 슬립폼시스템을 개발하여 제작오차 및 시공 시 시행착오를 최소화하였음. 또한 슬립폼 최적기 상승기술을 개발하여 공기단축, 안전성 및 콘크리트면 품질을 향상을 유도하였음. 그리고 변단면에 대한 자동화기술을 개발하여 정밀 형상 관리, 공사비 절감 및 작업 시간 단축을 가능하게 하였고, GPS를 이용한 시공정밀도 및 형상관리 기술을 개발하여 시공 정밀도를 확보하고 기후 영향과 시준점 영향을 최소화하였음. 경량 GFRP 모듈형 패널 기술을 개발하여 거푸집 설치 및 해체 시간을 단축시키고 고소작업 안전성을 향상시켰으며 고른 콘크리트 품질을 확보하였음.

∘ 2단계에는 1단계에서 개발한 핵심요소기술을 검증하고 보완하였음. 1주탑 및 2주탑에 대한 변단면 슬립폼시스템을 설계 및 제작하여 성공적으로 2회의 시험시공을 완료함으로써 핵심요소기술에 대한 검증을 수행하였음.

∘ 3단계에는 개발기술의 자동화 보완과 실용화를 위해 2회의 시험 시공을 추가로 수행하고 3건의 기술실시계약을 체결하였으며, 건설신기술을 등록하는 성과를 얻었음.

(출처 : 보고서 요약서 3p)

Abstract ▼

Ⅳ. Results
This research was launched on November 6th, 2009, and was implemented in three stages starting from the 2nd year to the 8th year of the TRM (Technical Road Map) of the Super Long Span Bridge R&D Center. The goal of the research is “Development of equipment and methods for the accelerat

Ⅳ. Results
This research was launched on November 6th, 2009, and was implemented in three stages starting from the 2nd year to the 8th year of the TRM (Technical Road Map) of the Super Long Span Bridge R&D Center. The goal of the research is “Development of equipment and methods for the accelerated erection of high concrete pylons to secure technological independence and international competitiveness”. For the efficient execution of the project, the research is subdivided into 3 core technologies that are: “slip-form equipment and method for high pylons with tapered-section”, “configuration control of pylons higher than 400 m using GPS”, and “lightweight slip-form modules for tapered sections”.

The first stage of the research ran during 28.7 months from the 2nd year to the 4th year of the program and was dedicated to the identification of original technologies and the development of the details for the core technologies.
Concretely, the tapered slip-form system applying BIM-based 3D design and virtual erection was developed to minimize construction and fabrication errors.
In addition, the lift-up time of the slip-form was optimized to shorten the erection period and improve the safety and quality of the concrete surface.
Moreover, automation technology for tapered sections was developed to achieve precise configuration control, cost reduction and accelerated erection.
Configuration control using GPS was developed to secure the accuracy of erection and minimize the effects of the weather and control points. Lightweight GFRP modular panels were developed to shorten the time spent for the assemblage and dismantlement of the forms, improve the safety of works at high altitude and secure even quality of concrete.

The second stage lasted for 24 months from the 5th year to the 6th year of the program. This stage verified and complemented the core technologies developed in the 1st stage. The tapered slip-form systems for 1-pylon and 2-pylon were designed and fabricated, and were used successfully in 2 trial erections.

The third stage ran during 21 months from the 7th year to the 8th year of the program. This stage implemented 2 additional trial erections to supplement the automation of the system developed in the 1st and 2nd stages. Three Technology License Agreements were contracted and the developed technology was registered as Construction Innovation Technology.

The following conclusions can be drawn from these 3 stages of research.
(1) Research was implemented on the design and fabrication of the tapered slip-form system for the erection of concrete pylons with tapered sections varying 3-dimensionally. The constitution of the slip-form system was analyzed and solutions of the slip-form were derived to deal with tapered sections. Based upon the developed key technologies, design drawings of the slip-form system necessary for two trial erections were prepared and design verification was executed using BIM. The slip-form system fabricated based on the design drawings was installed and applied successfully for the trial erection of tapered concrete pylons. This demonstrated the safety and efficiency of the slip-form system developed in this research.

(2) In the traditional slip-form method, the erection relied on the experience or on the use of a probe bar. In this research, the degree of setting of the concrete placed inside the slip-form is assessed using ultrasonic waves (surface waves) and the optimal lift-up time of the slip-form was studied. To that goal, penetration resistance test, compressive strength test, and test measuring the speed of the surface wave were conducted simultaneously considering various parameters including the mix composition of concrete and the curing temperature. The results enabled to derive the speed of the surface wave for which the stable quality of concrete could be secured. The so-derived speed of the surface wave was applied in the trial erection and helped in the successful construction of a tapered concrete pylon. Throughout 4 trial constructions, it was verified that very efficient erection could be achieved by lifting-up the slip form based on the speed of the surface wave proposed in this research.

(3) The previous method erected the tapered pylon by adjusting manually the spindle. This method is extremely inefficient and may even cause problems in the configuration control. In order to solve such problems, the wireless-controlled electric spindle (K-Spindle) was developed and its effectiveness was verified by applying it to the erection of a tapered pylon. The results of 2 trial constructions using the K-Spindle showed that individual and simultaneous control of the spindles could be done wirelessly and that the K-Spindle could deal rapidly with tapered sections. Since the rotation speed and direction of the K-Spindle can be adjusted easily, the slip-form can be enlarged or narrowed conveniently to fit to the desired shape of the pylon. The rotation speed can be increased according to the gear ratio of the applied gear box. This feature allows the K-Spindle to develop significantly larger torque than by manpower and to respond rapidly to the tapered section under any condition. A rain protection structure was adopted to enable operation regardless of the weather. In addition, the spindles can be switched to manual or automated mode in case of emergency so as to reflect the characteristics of the slip-form which operates non-stop 24 hours/day. Even if there is always a reserve electric power generator in ordinary sites to allow normal operation in emergency case, a manual control function was added to secure smooth operation of the slip-form even in extreme case where power supply is completely shut down.
Such extreme event was simulated during the trial construction to verify the normality of the operational process. Accordingly, the efficiency of the operation of the slip-form was magnified together with the realization of precise configuration control during the erection of the high tapered concrete pylon.

(4) A wireless remote configuration control system was developed to minimize the effect of external environment like weather and be free from the traditional measurement methods for the precise erection of the concrete tower by slip-forming. Here, research was conducted on data acquisition and processing techniques to secure the accuracy and achieve a measurement system applying GPS and tiltmeter in all-weather. Moreover, a unified system enabling to control automatically and wirelessly the hydraulic jacks based upon the measured data was developed. To that goal, an automated measurement module was developed to integrate the real-time GPS measurement and the tiltmeter located at the same position for the efficient configuration control of the 3-dimensionally varying shape of the pylon. The reliability of the data was secured through signal processing using the Kalman filter to improve the accuracy of the GPS measurement. In addition, the so-called KICS (KICT Integrated Configuration control System) was applied experimentally to the Ulsan Bridge site and the effect of the forms and crane tower was evaluated to improve the field applicability of the concrete tapered pylon. In view of the 4 trial constructions of tapered concrete pylons using the slip-form system developed in this research, this system enabled to execute successfully the configuration control of the structures.

(5) The shape and module of forms made of GFRP were developed to achieve lightweight slip-forms. Analysis was conduced to verify if the GFRP forms developed through analytical and experimental studies secured higher performance than the conventional ones. The structural analysis and experimental results revealed that, compared to the steel form, the GFRP form offered better structural performance and remarkable insulation effect. The insulation effect could keep the temperature constant during the curing of concrete and provided positive effect in the quality of concrete. The modularization of the GFRP forms eased the assemblage and dismantlement.
The connection between the modular GFRP form and the slip-form system was developed so as to shorten significantly the time required for the installation of the forms and, in turn, reduce the whole slip-forming period. Since the developed GFRP form module are made of waterproof material, the module can thrust out humidity during the curing of concrete. Such property reduces the frictional force developed during the lift-up between the slip-form and concrete, and is advantageous in term of the quality of concrete. Finally, a series of tests using the GFRP form showed that the surface of the concrete structure was better than that obtained using steel form.

(6) The core technologies developed for the slip-form system for tapered concrete pylons were probated through 3 mockup tests, and their performances were supplemented and improved by means of 4 trial constructions. Especially, the 4 trial constructions involved full-scale bridge pylons and were completed successfully, which showed that the developed core technologies could be applied on site without problem. The detailed items of the verification and application are as follows.

The core technologies developed in the first stage were integrated and resulted in the fabrications of 3 mockup slip-form systems that were used in verification tests. In the first mockup test, a small-scale slip-form system made of steel and GFRP forms and a cross-section of 40×40 cm was fabricated and used to place concrete with various layers of 25 cm prior to execute the wireless hydraulic jack control program of the configuration control system. The frictional force was measured according to the lift-up of the slip-form when the steel and GFRP forms were lifted separately and when the forms were lifted concurrently. The test enabled to verify the excellence of the concrete surface after construction as well as the insulation of the GFRP form. In the second mockup test, steel and GFRP forms with cross-section of 40×40 cm and height of 1.2 m were fabricated and 25 cm-thick layers of concrete were placed every hour. Here also, the hydraulic jack control program of the configuration control system was also used similarly to the slip-forming of an actual concrete pylon.
The steel and GFRP forms were lifted concurrently to achieve two 2-m high columns. The ultrasonic wave module was installed at the foot of the form to determine the lift-up time of the slip-form using the ultrasonic wave speed.
This enabled to verify the possibility to operate efficiently the slip-form system using the ultrasonic wave device. The third mockup test was conducted using the GPS module and a fabricated slip-form system. The test erected simultaneously 2 concrete columns of 1.8 m by remote control of the slip-form system using the configuration control system. The test showed the absence of problem or deflection in the connection after the placing of concrete and after slip-up.

Apart from the mockup tests, four trial constructions were conducted to verify the performance of the developed core technologies and improve their field applicability. The first trial construction intended to verify the applicability of the integration of the core technologies developed in this research. The slip-form system was designed and fabricated to reflect all the core technologies in order to prove the feasibility of the erection of the tapered pylon using the developed slip-form system. At that time, it was believed that the R&D was completed for the core technologies of the tapered slip-form method.
However, unexpected problems occurred in the design stage and were supplemented. Especially, the necessity to secure the comfort of the technicians and the working space was seen to have been ignored in the design stage. The second trial construction erected simultaneously two tapered section by slip-forming using a lattice girder. The two-tapered legs of the concrete pylon, similar to those usually applied in long span bridges, were successfully erected simultaneously up to a height of 10 m. Even if it was not initially planned, a prototype of the electro-powered spindle system enabling to automatize the erection of the tapered section that was previously done manually by manpower was applied. The convenience of work was ameliorated by improving the connection of the GFRP form module. The cable anchor was inserted as done during the erection of the pylon of ordinary cable stayed bridges so as to verify the field applicability. The third trial construction verified the automated operation of the tapered slip-form system. The automated system of the electro-powered spindle was applied in every part of the tapered section work.
This trial construction enabled to verify the shortening of the working time and the reduction of manpower as well as the possibility to execute the configuration control. The fourth trial construction verified the durable performance of the wireless electro-powered spindles and the field applicability of the construction new technologies. The automated system of the tapered slip-form system that was abandoned in place during 8 months after the third trial construction was seen to operate properly. The previously erected pylon specimen was raised additionally by 2 m. Note that the wireless electro-powered were not removed after the third trial erection and were let in place to be exposed to the external environment during 8 months. Despite of such long exposure, all the 32 automated systems operated normally and enabled to conduct effectively the tapered section.

(출처 : Summary 18p)

목차 Contents

• 표지 ... 1
• 제출문 ... 2
• 보고서 요약서 ... 3
• 요약문 ... 4
• Summary ... 14
• 목차 ... 26
• Contents ... 30
• 제 1 장 연구개발과제의 개요 ... 34
• 제 1 절 연구개발 기술의 정의 및 필요성 ... 34
• 제 2 절 연구개발 목표 및 내용 ... 40
• 1. 연구개발의 최종목표 ... 40
• 2. 연차별 연구목표 및 연구내용 ... 40
• 제 2 장 국내외 기술개발 현황 ... 44
• 제 1 절 국내 기술 동향 ... 44
• 1. 국내 장대교량 주탑 현황 ... 44
• 2. 공기단축형 슬립폼 공법 기술 현황 ... 47
• 3. 콘크리트 고주탑 시공관리 기술 현황 ... 56
• 제 2 절 해외 기술 동향 ... 62
• 1. 해외 장대교량 주탑 현황 ... 62
• 2. 해외 슬립폼 공법 기술 현황 ... 81
• 3. 해외 시공중 형상관리 기술 현황 ... 91
• 제 3 장 연구개발 수행 내용 및 결과 ... 100
• 제 1 절 변단면 슬립폼 시스템 설계 및 제작기술 ... 100
• 1. 개요 ... 100
• 2. 기존 슬립폼시스템의 구성 및 설계기술 분석 ... 102
• 3. 변단면 슬립폼시스템의 프로토타입 설계 ... 112
• 4. 2차 시험 시공에 적용할 변단면 슬립폼시스템 설계 ... 127
• 5. BIM을 이용한 슬립폼시스템의 설계 보완 ... 135
• 6. 2차 시험시공에 의한 검증 및 보완 ... 139
• 7. 3차 시험시공에 의한 검증 및 보완 ... 142
• 8. 소결론 ... 144
• 제 2 절 슬립폼 최적기 상승기술 및 변단면 자동화기술 개발 ... 146
• 1. 개요 ... 146
• 2. 슬립폼 최적기 상승기술 ... 148
• 3. 슬립폼 변단면 자동화기술 ... 158
• 4. 소결론 ... 166
• 제 3 절 고주탑 형상 및 시공정밀도 관리시스템 개발 ... 168
• 1. 개요 ... 168
• 2. KICS(KICT Integrated Configuration control System) 개발 ... 169
• 3. 시험시공 중 형상 관리를 통한 검증 및 보완 ... 172
• 4. GPS 신호 처리 모듈 개발 ... 179
• 5. 소결론 ... 187
• 제 4 절 경량 슬립폼시스템 개발 ... 188
• 1. 개요 ... 188
• 2. GFRP 거푸집의 역학적 특성 ... 189
• 3. GFRP 모듈형 패널 개발 ... 202
• 4. 소결론 ... 206
• 제 5 절 목업실험 및 시험시공 ... 208
• 1. 개요 ... 208
• 2. 목업실험 ... 209
• 3. 시험시공 ... 218
• 4. 소결론 ... 229
• 제 6 절 결론 ... 232
• 제 4 장 목표달성도 및 관련분야에의 기대성과 ... 238
• 제 1 절 연구목표 달성도 ... 238
• 1. 연차별 성과지표 달성도 ... 238
• 2. 연차별 주요 산출물 ... 249
• 3. 연차별 연구비 집행 내역 ... 255
• 제 2 절 기대성과 및 파급효과 ... 264
• 1. 기술적 측면 ... 264
• 2. 사회·경제적 측면 ... 265
• 3. 전략적 측면 ... 273
• 제 5 장 연구개발결과의 활용계획 ... 274
• 제 1 절 연구결과의 활용방안 ... 274
• 1. 활용방안 종합 ... 274
• 2. 성과물 특성에 따른 활용방안 ... 275
• 제 2 절 연구결과의 기업 활용방안 ... 276
• 1. 참여기업의 현황분석 ... 276
• 2. 참여기업별 연계방안 및 추진전략 ... 280
• 제 3 절 타 산업에 미치는 효과 ... 282
• 제 4 절 정부 정책과의 연계 방안 ... 284
• 1. 정부 정책과의 연계 방안 ... 284
• 2. 정부 및 관련 공공기관과의 협조 방안 ... 284
• 제 5 절 관련 후속연구개발의 전망 ... 286
• 제 6 장 연구개발과정에서 수집한 해외과학기술정보 ... 288
• 제 1 절 중국 장대교량 주탑시공 현황 분석 ... 288
• 1. 수통대교 ... 289
• 2. 강소양자대교 ... 291
• 3. 태주장강대교 ... 293
• 4. 상해소재 사장교 ... 296
• 제 2 절 교량의 시공방법 현황 분석 ... 300
• 1. 교량 형식과 시공 방법 ... 301
• 2. Jacking and Skidding ... 305
• 3. Movable Scaffolding Systems ... 307
• 4. Form-Traveller Systems ... 307
• 5. Precast Full Span Method ... 308
• 제 7 장 참고문헌 ... 312
• 끝페이지 ... 317