JP7502649B2 - Tunnel manufacturing method and filling structure - Google Patents

Description

This disclosure relates to a tunnel manufacturing method and a filling structure.

Tunnel linings include the support structure made of sprayed concrete, which has become mainstream in recent years, and tunnel structures made using the sheet pile method, which was previously used. With the sheet pile method, the steel arch supports and sheet piles can get in the way, leaving cavities between the tunnel inner wall (e.g., the lining concrete) and the ground behind it (e.g., the ground).

The inner wall of a tunnel includes a primary area that receives pressure from the ground, and a passive area that receives internal stress from the primary area and tries to deform towards the ground. The passive area is prevented from displacing by receiving a reaction force from the ground located behind it. However, if a cavity exists behind the passive area, the passive area cannot receive the reaction force from the ground, leading to a lack of structural load-bearing capacity of the inner wall of the tunnel.

Patent documents 1 and 2 disclose a method of forming through holes in the tunnel inner wall (e.g., sheet piles or lining concrete) and filling a filler (e.g., urethane foam) into the cavity at the back of the tunnel through the through holes. Patent document 3 discloses a cement-based filler. Patent document 4 discloses a filler containing urethane foam and lightweight aggregate.

JP 2007-146522 A JP 2013-91981 A JP 2005-163526 A JP 2017-53207 A

To reinforce the tunnel walls, the cavities at the rear of the tunnel are sometimes filled with a filling material. Such tunnel walls may have relatively large openings. If these openings are connected to the cavity at the rear of the tunnel, the filling material may flow out of the cavity at the rear of the tunnel through the openings into the interior of the tunnel.

The present disclosure provides a tunnel manufacturing method and filling structure that prevents the filling material from leaking through the opening.

A method for manufacturing a tunnel according to one aspect of the present disclosure includes covering an opening formed in an inner wall of the tunnel that leads to a cavity located between the inner wall of the tunnel and the ground with a plate material. The method further includes filling the cavity with a filler material through a through hole provided in the inner wall of the tunnel or the plate material.

A filling structure according to another aspect of the present disclosure is a filling structure filled in a cavity located between the inner wall of a tunnel and the ground. The filling structure includes a plate material that covers an opening formed in the inner wall of the tunnel that leads to the cavity. The filling structure further includes a filling layer formed in the cavity and in contact with the plate material.

The above tunnel manufacturing method can prevent leakage through openings in the filling material.

FIG. 2 is a cross-sectional view of a packing structure according to an embodiment of the present disclosure. 1 is a flow chart illustrating a process for manufacturing a tunnel according to an embodiment of the present disclosure. FIG. 2 is a cross-sectional view of a tunnel during manufacture according to an embodiment of the present disclosure. FIG. 2 is a cross-sectional view of a tunnel during manufacture according to an embodiment of the present disclosure. FIG. 2 is a cross-sectional view of a tunnel during manufacture according to an embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a tunnel during manufacture according to another embodiment of the present disclosure.

As shown in FIG. 1, the filling structure 10 is filled in a cavity 43 located between a tunnel inner wall 30 and the ground 42. The tunnel inner wall 30 is made of, for example, concrete. The tunnel inner wall 30 has an inner peripheral surface 31 facing the tunnel interior space 41 and an outer peripheral surface 32 facing the ground 42.

The tunnel inner wall 30 further has an opening 33 extending from the inner circumferential surface 31 to the outer circumferential surface 32. The opening 33 is, for example, an opening remaining due to the removal of an object installed in the tunnel, such as a sign, lighting, signal, or ventilation device, from the tunnel inner wall. Alternatively, the opening 33 is, for example, an opening formed by the peeling off of a piece of concrete from the tunnel inner wall 30. The opening 33 has a size and shape of, for example, a square of 600 mm on each side, but is not limited to this.

The tunnel inner wall 30 further has a through hole 34 extending from the inner peripheral surface 31 to the outer peripheral surface 32. The through hole 34 is a hole for injecting a filler material from a filler material delivery pump installed in the tunnel inner space 41 into the cavity 43. The through hole 34 has a size and shape of, for example, a circle with a diameter of 32 mm, but is not limited to this. The size of the through hole 34 may be smaller than the size of the opening 33.

The filling structure 10 includes a plate material 11 that covers the opening 33. The plate material 11 includes, for example, resin, wood, metal, ceramics, carbon fiber, or a composite material thereof. In this embodiment, the plate material 11 is made of urethane foam. The plate material 11 may have a thickness of, for example, 30 mm, but is not limited to this. The plate material 11 may include an ultraviolet protection layer. The ultraviolet protection layer may be made of fiber or epoxy resin.

The filling structure 10 further includes a filling layer 12 formed in the cavity 43 and in contact with the plate material 11. The filling layer 12 includes, for example, a resin. In this embodiment, the filling layer 12 is made of urethane foam. The urethane foam may be, but is not limited to, a urethane foam that expands in volume by 30 to 50 times (preferably, 36 to 44 times) upon foaming. The urethane foam may have a curing time of about 65 seconds, but is not limited to this.

As described above, in this embodiment, the plate material 11 is made of urethane foam. The plate material 11 made of urethane foam has the following advantages. For example, urethane foam is lightweight, so the impact of the plate material 11 on the tunnel inner wall 30 can be minimized. Urethane foam can be easily processed with a simple cutting tool such as a utility knife, so the plate material 11 can be easily shaped on-site. Because urethane foam is the same material as the filling layer 12 (urethane foam), the plate material 11 adheres well to the filling layer 12, which minimizes the possibility of the plate material 11 peeling off and falling from the filling layer 12.

Figure 2 shows an example of a tunnel manufacturing process. The workers in each of the following steps may be the same or different.

The worker covers the opening 33 leading to the cavity 43 with the plate material 11 (step S1). For example, as shown in FIG. 3, the plate material 11 may be located in the cavity 43 and disposed on the outer peripheral surface 32 of the tunnel inner wall 30. The opening 33 has an opening area 35 on the cavity 43 side. The plate material 11 has an area 13 larger than the opening area 35. For example, when the opening 33 is a square, the plate material 11 may be a square having sides longer than the sides of the opening 33 and shorter than the diagonal line of the opening 33. Alternatively, the plate material 11 may be elastically deformable to an extent that it can pass through the opening 33. Such a plate material 11 can be carried from the tunnel inner space 41 to the cavity 43 through the opening 33.

The worker then forms through holes 34 in the tunnel inner wall 30 (step S2). Each through hole 34 is used to inject filler into a certain range (e.g., a radius of 2 m) within the cavity 43. As shown in FIG. 3, multiple through holes 34 may be formed at intervals. The through holes 34 may be formed in the plate material 11.

The worker then fills the cavity 43 with the filler material through the through hole 34 (step S3). Specifically, the worker connects an injection hose (or pipe) connected to a filler material delivery pump to the through hole 34. The worker drives the filler material delivery pump to fill the cavity 43 with the filler material through the through hole 34.

As shown in FIG. 5, the plate material 11 has elasticity and may be deformed by being pressed by the expanding filler material in the cavity 43. Specifically, the plate material 11 may bend toward the tunnel interior space 41. The worker can detect the deformation of the plate material 11 visually or with a sensor and determine that the filler material has been properly filled into the cavity 43. The worker may use a cutting tool to cut off the excessively protruding portion of the plate material 11.

The worker then removes the injection hose connected to the through hole 34 to complete the filling material injection process. For example, the injection hose can be pulled out, but if the injection hose is made of resin, it can be easily cut.

In the process of FIG. 2, the through hole 34 is formed after the opening 33 is covered with the plate material 11. Conversely, the through hole 34 may be formed and then the opening 33 may be covered with the plate material 11. Also, as described above, the plate material 11 may have the through hole 34. The plate material 11 may be placed on the tunnel inner wall 30 and then the through hole 34 may be formed in the plate material 11. Conversely, the through hole 34 may be formed in the plate material 11 and then the plate material 11 may be placed on the tunnel inner wall 30.

As shown in FIG. 5, the plate material 11 is disposed on the outer peripheral surface 32 of the tunnel inner wall 30. Alternatively, as shown in FIG. 6, the plate material 11 may be disposed within the opening 33. For example, the plate material 11 has an outer peripheral surface 14. The opening 33 has an inner peripheral surface 36. The outer peripheral surface 14 of the plate material 11 faces the inner peripheral surface 36 of the opening 33.

In the example of FIG. 6, the plate material 11 is placed in the opening 33 without any gap or with a small gap. In the process of filling the cavity 43 with the filling material, the plate material 11 may be supported by a structure installed in the tunnel inner space 41. The structure prevents the plate material 11 from shifting in position due to the pressure of the filling material. Alternatively, the plate material 11 may be fixed in the opening 33 without any other structure by being pressed into the opening 33. For example, the plate material 11 may have elasticity, be larger than the opening 33 in its natural state, and be placed in the opening 33 in a compressed state.

As shown in FIG. 6, the plate material 11 may be arranged to conform to the inner periphery 31 of the tunnel inner wall 30 to improve appearance (design).

Although one embodiment of the present disclosure has been described above, the present disclosure is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention. In particular, the multiple embodiments and modifications described in this specification can be combined as desired.

REFERENCE SIGNS LIST 10 Filled structure 11 Plate material 12 Filled layer 30 Tunnel inner wall 31 Inner peripheral surface 32 Outer peripheral surface 33 Opening 34 Through hole 41 Tunnel inner space 42 Ground 43 Cavity

Claims (12)

covering an opening formed in an inner wall of the tunnel, the opening leading to a cavity located between the inner wall of the tunnel and the ground, with a plate material;
and filling the cavity with a filler material through a through hole provided in the inner wall of the tunnel or the plate material,
The plate has an outer circumferential surface,
The opening has an inner periphery.
the step of covering the opening with a plate material includes disposing the plate material within the opening such that the outer circumferential surface of the plate material faces the inner circumferential surface of the opening;
How tunnels are manufactured. covering an opening formed in an inner wall of the tunnel, the opening leading to a cavity located between the inner wall of the tunnel and the ground, with a plate material;
and filling the cavity with a filler material through a through hole provided in the inner wall of the tunnel or the plate material,
the plate material has an area larger than an opening area of the opening on the cavity side, is elastically deformable to an extent that the plate material can pass through the opening, is carried into the cavity through the opening, and is disposed in the cavity.
How tunnels are manufactured. covering an opening formed in an inner wall of the tunnel, the opening leading to a cavity located between the inner wall of the tunnel and the ground, with a plate material;
and filling the cavity with a filler material through a through hole provided in the inner wall of the tunnel or the plate material,
The plate material has elasticity,
The filler is filled until the plate material is pressed by the filler and deformed.
How tunnels are manufactured. covering an opening formed in an inner wall of the tunnel, the opening leading to a cavity located between the inner wall of the tunnel and the ground, with a resin plate;
and filling the cavity with a filler material through a through hole provided in the tunnel inner wall or the plate material so as to contact the plate material.
How tunnels are manufactured. covering an opening formed in an inner wall of the tunnel, the opening leading to a cavity located between the inner wall of the tunnel and the ground, with a plate material;
and filling the cavity with a filler material through a through hole provided in the inner wall of the tunnel or the plate material,
The filler is urethane foam.
How tunnels are manufactured. The tunnel manufacturing method according to any one of claims 1 to 5, wherein both the filling material and the plate material are made of urethane foam. A filling structure filled in a cavity located between the inner wall of a tunnel and the ground,
An opening formed in an inner wall of the tunnel, the opening being connected to the cavity, and a plate material covering the opening;
A filling layer formed in the cavity and in contact with the plate material;
Equipped with
The plate has an outer circumferential surface,
The opening has an inner periphery.
A filling structure in which the plate is placed in the opening such that the outer circumferential surface of the plate faces the inner circumferential surface of the opening. A filling structure filled in a cavity located between the inner wall of a tunnel and the ground,
An opening formed in an inner wall of the tunnel, the opening being connected to the cavity, and a plate material covering the opening;
A filling layer formed in the cavity and in contact with the plate material;
Equipped with
The plate has a through hole and is disposed within the cavity, forming a filling structure. A filling structure filled in a cavity located between the inner wall of a tunnel and the ground,
An opening formed in an inner wall of the tunnel, the opening being connected to the cavity, and a plate material covering the opening;
A filling layer formed in the cavity and in contact with the plate material;
Equipped with
The plate material is a filling structure that has elasticity and bends toward the interior of the tunnel. A filling structure filled in a cavity located between the inner wall of a tunnel and the ground,
An opening formed in an inner wall of the tunnel, the opening being connected to the cavity, and a resin plate material covering the opening;
A filling layer formed in the cavity and in contact with the plate material;
A filling structure comprising: A filling structure filled in a cavity located between the inner wall of a tunnel and the ground,
An opening formed in an inner wall of the tunnel, the opening being connected to the cavity, and a plate material covering the opening;
A filling layer made of urethane foam formed in the cavity and in contact with the plate material;
A filling structure comprising: The filling structure according to any one of claims 7 to 11, wherein both the filling layer and the plate material are made of urethane foam.