JP7702916B2 - Invert formwork manufacturing device, invert construction system and invert construction method - Google Patents

Description

The present invention relates to an invert formwork manufacturing device, an invert construction system, and an invert construction method.

In mountain tunnels (such as NATM), the standard support pattern changes depending on the ground class, and there are sections with inverts and sections without inverts. Figure 1 shows a tunnel T with an invert.
In the section with the invert, the joint (haunch C3) between the lining concrete C1 and the invert concrete C2 is generally formed in a curved cross section. The curved cross section of the haunch C3 (upper end of the invert) is constructed using an invert formwork with a curved surface (concrete side surface) (see, for example, Patent Document 1). In addition, the invert is generally constructed by constructing the left and right half cross sections at a time to ensure a passage from the tunnel entrance to the face.
Therefore, the construction of the invert is carried out by assembling formwork such as a bottom formwork, a vertical formwork, and an invert formwork on the floor surface Ts formed by excavation, and then pouring concrete. Such construction of the invert requires multiple workers. Also, the assembly of the formwork is generally done manually, which is time-consuming.

JP 2016-084629 A

From this perspective, the objective of the present invention is to propose an invert formwork manufacturing device, an invert construction system, and an invert construction method that reduce the amount of work required for tunnel invert construction and the number of workers required for construction.

In order to solve the above problems, the invert formwork manufacturing apparatus of the present invention manufactures formwork for inverts by ejecting a solidification material onto a tunnel floor attachment surface, and is equipped with a pair of fixed beams arranged at a distance above the tunnel floor attachment surface, a movable beam movably mounted horizontally along the pair of fixed beams, a nozzle movably mounted along the movable beams, and a solidification material supply means for supplying solidification material to the nozzle.
In addition, the invert construction method of the present invention includes the steps of excavating the bottom of the tunnel and laying a floor, installing the invert formwork manufacturing equipment, using the invert formwork manufacturing equipment to eject the solidification material to form a transverse formwork and a longitudinal formwork, and pouring concrete into the space surrounded by the transverse formwork and the longitudinal formwork.
In such an invert construction method, it is desirable to use an invert construction system that includes, in addition to the invert formwork manufacturing apparatus, a concrete pouring device having a pouring movable beam that is movably suspended along the pair of fixed beams, a plurality of pouring hoses attached to the pouring movable beam, and a concrete supply means for supplying concrete to the pouring hoses.

According to the invert form manufacturing device and the invert construction method, the form is formed by discharging the solidification material from a nozzle that moves back and forth and left and right, which is simpler than assembling the form by hand. Therefore, it is possible to reduce the number of workers.
The invert form manufacturing device may further include a 3D scanner that is movable along the movable beam. When the invert form manufacturing device includes a 3D scanner, the 3D scanner is used to scan the tunnel floor attachment surface, and the difference between the shape of the tunnel floor attachment surface and the design cross section is calculated. The solidification material is then discharged according to the difference to form a horizontal form and a vertical form. In this way, a form corresponding to the on-site shape can be easily formed.

The invert formwork manufacturing device, invert construction system, and invert construction method of the present invention make it possible to reduce the amount of work required for tunnel invert construction and to cut the number of workers required for construction.

FIG. 2 is a cross-sectional view showing a tunnel having an invert. 1 is a plan view showing an invert form manufacturing apparatus of the present embodiment. FIG. FIG. 2 is a cross-sectional view showing an invert form manufacturing apparatus. FIG. 2 is a longitudinal sectional view showing an invert form manufacturing apparatus. FIG. 2 is a plan view showing a concrete pouring device. FIG. 2 is a cross-sectional view showing a concrete pouring device. FIG. 2 is a longitudinal sectional view showing a concrete pouring device. 2 is a flowchart showing the steps of the invert construction method of the present embodiment. FIG. FIG. 13 is a cross-sectional view showing the haunch construction process.

In this embodiment, a method for constructing an invert in a tunnel T having an invert will be described (see FIG. 1). In this embodiment, a form for the invert is formed using an invert construction system 1, and the invert is formed by pouring concrete into the form. The form is formed using a so-called 3D printer.
The invert construction system 1 comprises an invert formwork manufacturing device 2 (Figures 2 to 4) and a concrete pouring device 3 (Figures 5 to 7).
The invert form manufacturing device 2 is a device that manufactures a form for an invert on a tunnel floor attachment surface Ts by discharging a solidification material onto the floor attachment surface. An overview of the invert form manufacturing device 2 is shown in Figures 2 to 4. As shown in Figure 2, the invert form manufacturing device 2 includes a pair of fixed beams 21, 21, a movable beam 22, a nozzle 23, a solidification material supplying means 24, and a 3D scanner 25.

As shown in FIG. 2 and FIG. 3, the pair of fixed beams 21, 21 are provided at a distance from each other above the tunnel floor attachment surface Ts. The pair of fixed beams 21, 21 constitute a part of a frame for supporting the nozzle 23 and the 3D scanner 25. In this embodiment, the fixed beams 21 are provided at the side and center of the tunnel along the tunnel axis direction (Y direction). The fixed beams 21 are made of steel (H-shaped steel in this embodiment). The fixed beam 21 provided at the center of the tunnel is supported by supports 21a, 21a made of steel (e.g., H-shaped steel or channel steel) erected on the tunnel floor attachment surface Ts, as shown in FIG. 3 and FIG. 4. In this embodiment, supports 21a are provided at both ends of the fixed beam 21. A steel material (e.g., a channel material) is fixed to the supports 21a, 21a arranged at the ends in the tunnel axis direction as a support member (bracket) 21b, and the fixed beam 21 is fixed on the support member 21b. In addition, the fixed beam 21 installed on the side of the tunnel (right side in FIG. 3) is supported by a support member (bracket) 21c (e.g., channel steel) fixed to the shoring. As shown in FIG. 3, the fixed beams 21, 21 installed on the left and right are installed to be at the same height. In addition, the fixed beams 21, 21 arranged on the left and right are connected by connecting members 21d, 21d made of steel materials (e.g., angle members) that are horizontally installed at both ends. In other words, the frame is formed by combining the fixed beam 21, the support column 21a, the support members 21b, 21c, and the connecting members 21d, 21d.

As shown in FIG. 3, the movable beam 22 is supported on a pair of fixed beams 21, 21. The movable beam 22 can move along the pair of fixed beams 21, 21. That is, the movable beam 22 can move along the tunnel axis direction (Y direction). The movable beam 22 is made of steel such as H-shaped steel, and is supported on the fixed beams 21, 21 via a moving means (not shown) such as running wheels or rollers that run on the fixed beams 21, 21. In this embodiment, the end of the movable beam 22 is inserted between the upper and lower flanges of the fixed beam 21 together with the moving means. The movement of the movable beam 22 in the tunnel axis direction is controlled by a control means (not shown).

The nozzle 23 is provided on the movable beam 22. The nozzle 23 is movable along the movable beam 22. That is, the nozzle 23 moves along the movable beam 22 in the tunnel cross direction (X direction) and along the tunnel axis direction (Y direction) together with the movable beam 22, so that it can move over the entire construction range in a plan view. The nozzle 23 is also provided so as to be movable in the vertical direction (Z direction) relative to the movable beam 22. The nozzle 23 in this embodiment is configured to be movable by a moving means (not shown) such as a running wheel or roller that runs along the flange of the movable beam 22. The movement of the nozzle 23 in the tunnel cross direction (movement along the movable beam 22) and the movement in the vertical direction are controlled by a control means (not shown). A solidification material hose 26 extended from the solidification material supplying means 24 is connected to the nozzle 23. The nozzle 23 discharges the solidification material transported through the solidification material hose 26 toward the flooring surface.

The solidification material supplying means 24 supplies the solidification material to the nozzle 23 via the solidification material hose 26. The solidification material is, for example, a hydraulic material such as mortar or concrete. The solidification material supplying means 24 includes a hopper 24a and a concrete pump 24b. The solidification material transported via the agitator vehicle and poured into the hopper 24a is pumped by the concrete pump 24b through the solidification material hose 26 to the nozzle 23. In this embodiment, the solidification material hose 26 is extended in the tunnel axial direction (Y direction) at the top of the tunnel via a pulley 26a provided at the top of the tunnel, and then connected to the nozzle 23.

The 3D scanner 25 is provided on the movable beam 22 so as to be movable along the movable beam 22. In this embodiment, the 3D scanner 25 is integral with the nozzle 23 or attached to the nozzle 23, and is movable together with the nozzle 23 along the movable beam 22 in the tunnel transverse direction (X direction), and is also movable together with the movable beam 22 along the tunnel axial direction (Y direction). The measurement results by the 3D scanner 25 are transmitted to a terminal (not shown) such as a computer, tablet, or smartphone.

The concrete pouring device 3 pours concrete into the formwork formed by the invert formwork manufacturing device 2. Figures 5 to 7 show the concrete pouring device 3. As shown in Figure 5, the concrete pouring device 3 includes a movable pouring beam 31, a pouring hose 32, a concrete supply means 33, and a vibrator 34.
As shown in FIG. 5 and FIG. 6, the casting movable beam 31 is horizontally supported on a pair of fixed beams 21, 21 so as to be movable along the pair of fixed beams 21, 21. That is, the casting movable beam 31 is movable along the tunnel axis direction (Y direction). The casting movable beam 31 is made of steel such as H-shaped steel, and is horizontally supported on the fixed beams 21, 21 via a moving means (not shown) such as a running wheel or roller that runs on the fixed beams 21, 21. In this embodiment, the end of the casting movable beam 31 is inserted between the upper and lower flanges of the fixed beam 21. The casting movable beam 31 may be moved automatically through a control means or manually in the tunnel axis direction. The casting movable beam 31 in this embodiment is provided separately from the movable beam 22 for constructing the formwork, and is disposed on the tunnel mouth side of the movable beam 22, but the casting movable beam 31 may be provided on the face side of the movable beam 22.

The concrete pouring hose 32 is provided on the movable concrete pouring beam 31 as shown in Figs. 5 and 6. In this embodiment, multiple concrete pouring hoses 32, 32, ... are provided on the movable concrete pouring beam 31 at arbitrary intervals. The concrete pouring hose 32 is suspended from the movable concrete pouring beam 31. A concrete hose 35 extending from a concrete supply means 33 is connected to the concrete pouring hose 32. In this embodiment, multiple vibrators 34, 34, ... are provided on the movable concrete pouring beam 31.

As shown in Figures 5 and 7, the concrete supply means 33 supplies concrete transported by an agitator vehicle or the like to multiple casting hoses 32, 32, ... via a concrete hose 35. The concrete supply means 33 consists of a concrete pump. The concrete transported into the tunnel is pressure-fed by the concrete supply means 33 (concrete pump) via the concrete hose 35 to the casting hose 32, and poured into the formwork 4 (the space surrounded by the transverse formwork 41 and the longitudinal formwork 42). The concrete hose 35 is connected to the casting hose 32 via a valve (not shown).

Next, a method for constructing an invert using the invert construction system 1 will be described. Figure 8 shows the steps of the invert construction method. As shown in Figure 8, the invert construction method includes a flooring process S1, an equipment installation process S2, a scanning process S3, an error calculation process S4, a formwork formation process S5, a pouring process S6, and a haunch construction process S7. In this embodiment, the construction of the invert is performed on one side at a time in the cross-sectional view of the tunnel, and the construction is performed in a section of 10.5 m in the tunnel axial direction.
The bedding process S1 is shown in Fig. 9. As shown in Fig. 9, the bedding process S1 is a process of excavating the bottom of the tunnel and bedding it (forming a tunnel bedding surface Ts). The tunnel bottom is excavated using an excavator such as a backhoe. The soil generated by the excavation is removed using a transportation means such as a truck or a belt conveyor. A slope S with a predetermined gradient is formed at the end of the construction range (excavation range).

The device installation process S2 is a process for installing the invert construction system 1 (see Figs. 2 to 4). First, the fixed beams 21, 21 are installed. In the device installation process S2, first, the support pillar 21a is erected in the center of the tunnel, and support members 21b, 21c are installed on the support pillar 21a and the tunnel side portions. Next, the fixed beam 21 is fixed to the support members 21b, 21c.
Next, the movable beam 22 is laid horizontally on the fixed beams 21, 21, and the nozzle 23 and the 3D scanner 25 are installed on the movable beam 22. In addition, the casting movable beam 31 is laid horizontally on the fixed beams 21, 21, and the casting hoses 32, 32, ... are installed on the casting movable beam 31.

The scanning process S3 is a process of scanning the tunnel floor attachment surface. The scanning of the tunnel floor attachment surface is performed by the 3D scanner 25 of the invert formwork manufacturing device 2. The 3D scanner 25 is moved in the tunnel transverse direction by moving along the movable beam 22, and the 3D scanner 25 is moved in the tunnel longitudinal direction by moving the movable beam 22 along the fixed beams 21, 21. In this way, the entire construction range of the invert is measured (scanned). The measurement results are transmitted to a computer or the like. At this time, the concrete pouring movable beam 31 is placed at the end of the fixed beam 21 on the tunnel mouth side.
The error calculation process S4 is a process of redesigning the form shape according to the on-site conditions. In the redesign process, the difference (construction error) between the shape of the tunnel floor attachment surface measured by the 3D scanner 25 and the design cross section is calculated, and the discharge amount of solidification material (form height) according to the on-site conditions is calculated. After that, the movement route (XYZ coordinates) of the nozzle 23 is set so that the form can be formed according to the position of the top surface of the invert as designed.

The formwork forming process S5 is a process of forming a formwork 4 on the flooring surface. The invert formwork manufacturing device 2 is used to form the formwork. In this embodiment, a plurality of transverse formworks (including hem formworks) 41, 41, ... are formed at intervals in the tunnel transverse direction, and a plurality of longitudinal formworks 42, 42, ... are formed at intervals in the tunnel transverse direction to form a lattice-shaped formwork 4. The transverse formwork 41 is created by discharging a solidifying material while moving the nozzle 23 along the movable beam 22 after placing the movable beam 22 at a predetermined position. The nozzle 23 is moved back and forth multiple times to stack the solidifying material to a predetermined height. The tunnel wall side end of the transverse formwork 41 has a curved surface shape according to the shape of the side of the invert. The longitudinal formwork 42 is created by discharging a solidifying material while moving the movable beam 22 along the fixed beam 21 with the nozzle 23 placed at a predetermined position of the movable beam 22. The movable beam 22 (nozzle 23) is moved back and forth multiple times to stack the solidification material to a specified height. After the horizontal formwork 41 and vertical formwork 42 are constructed, they are cured until they reach a specified strength.

The casting process S6 is a process of casting concrete in the space surrounded by the transverse formwork 41 and the longitudinal formwork 42 (see Figures 5 to 7). A concrete casting device 3 is used to cast the concrete. The concrete is cast by pouring concrete from the casting hoses 32, 32, ... with the casting movable beam 31 placed near the middle between the adjacent transverse formworks 41. At this time, the movable beam 22 for constructing the formwork is placed at the end of the face side of the fixed beam 21. As the concrete is poured, the poured concrete is compacted using the vibrator 34. The casting hose 32 and the vibrator 34 are placed at positions corresponding to the space between the adjacent longitudinal formworks 42. After the concrete is poured to a predetermined height and compacted, the casting movable beam 31 is moved and concrete is poured again. After a predetermined amount of concrete is poured into the formwork 4, the surface of the concrete is leveled along the top surface of the formwork 4 to finish the surface of the invert.

The haunch portion creation process S7 is a process for constructing the wall side end (haunch portion 5) of the invert having a curved surface. FIG. 10 shows the haunch portion creation process S7. As shown in FIG. 10, in this embodiment, the haunch portion 5 is created using the invert formwork manufacturing device 2. The haunch portion 5 is created by discharging the solidification material from the nozzle 23 while moving the movable beam 22 along the fixed beam 21 or moving the nozzle 23 along the movable beam 22 with the nozzle 23 disposed at a predetermined position of the movable beam 22 (a position corresponding to the haunch portion 5). The nozzle 23 is reciprocated multiple times to stack the solidification material to a predetermined height. After stacking the solidification material to a predetermined height, the nozzle 23 is shifted and the same operation is performed. The same operation is repeated multiple times to create the haunch portion 5 having a curved surface (triangular in cross section).
After the concrete has cured, the pouring joints are treated and the invert is backfilled.
The above steps from the bedding process S1 to the haunch construction process S7 constitute one cycle, and this cycle is repeated along the tunnel axis to construct the invert in the target section.

According to the invert construction system 1 and the invert construction method of the present embodiment, the solidification material is discharged from the nozzle 23 that moves back and forth and left and right to automatically form the formwork, which is simpler than assembling the formwork manually. Therefore, it is possible to reduce the number of workers.
In addition, by scanning the tunnel floor surface with a 3D scanner 25, a formwork 4 suited to the local conditions can be created using a 3D printer.
In addition, the curved surface of the invert side (haunch) can also be created using a 3D printer. This means that curved formwork is not required, the concrete pouring status can be visually checked, and quality defects such as junkers and pockmarks are less likely to occur.
By limiting the area where 3D printing is used, costs can be reduced and construction time can be shortened compared to constructing the entire invert using 3D printing.
Since it does not require large-scale equipment, it can be used even in the limited space inside a tunnel.
In addition, detailed construction records can be kept as digital data.

The present invention is not limited to the above-described embodiment, and each of the above-described components can be modified as appropriate without departing from the spirit of the present invention.
For example, the configuration of the frame supporting the movable beam 22 and the casting movable beam 31 is not limited to the structure shown in the above embodiment. For example, in the above embodiment, the fixed beam 21 arranged on the side is supported by shoring, but the fixed beam 21 on the side may be supported by a support.
In addition, in the above embodiment, the invert is constructed on one side at a time, but if the cross-sectional shape of the tunnel is small, it may be constructed along the entire width at the same time.
In addition, a concrete pouring device may be used as necessary. That is, concrete may be poured in the same manner as in the conventional construction method. When using high-fluidity concrete, compaction by a vibrator can be omitted.
In the above embodiment, the invert form manufacturing device 2 is provided with the 3D scanner 25, but the 3D scanner 25 may be omitted. In this case, the scanning step S3 and the redesign step S4 are omitted. Note that instead of the scanning step S3, a measurement using an optical distance meter or the like may be performed.
Measurement of the floor attachment surface using the 3D scanner 25 may be performed only at the locations where the horizontal formwork 41 and the vertical formwork 42 are formed.
A laser range finder may be used instead of the 3D scanner 25. When using a laser range finder, the distance from the laser range finder to the flooring surface Ts or the top surface of the solidification material is measured, and the solidification material is discharged according to the measurement result. The method of discharging the solidification material does not matter. It may be a method of repeatedly stacking thick layers of a hard-mixed self-supporting material, or a method of thinly stacking soft materials such as sprayed concrete while applying pressure.
In the above embodiment, the haunch portion is constructed using a 3D printer, but the haunch portion may be formed by pouring concrete into the formwork 4 in the same manner as the general portion (portion other than the haunch portion of the invert). At this time, the tunnel side wall side end of the cross formwork 41 is formed in a curved state according to the shape of the haunch portion. Then, the concrete surface is leveled along the upper surface of the cross formwork 41 at the tunnel side wall side end, which has a curved shape, to form the side end (haunch portion) of the invert into a curved shape.

REFERENCE SIGNS LIST 1 Invert construction system 2 Invert formwork manufacturing device 21 Fixed beam 22 Movable beam 23 Nozzle 24 Solidification material supplying means 25 3D scanner 3 Concrete pouring device 31 Pouring movable beam 32 Pouring hose 33 Concrete supplying means 4 Formwork 41 Transverse formwork 42 Vertical formwork

Claims (5)

An invert form manufacturing device that manufactures a form for an invert by discharging a solidification material onto a tunnel floor surface,
A pair of fixed beams spaced apart above the tunnel floor surface;
A movable beam movably supported along the pair of fixed beams;
A nozzle provided so as to be movable along the movable beam;
An invert form manufacturing apparatus characterized by comprising a solidification material supplying means for supplying a solidification material to the nozzle. The invert form manufacturing device according to claim 1, further comprising a 3D scanner movable along the movable beam. The invert form manufacturing apparatus according to claim 1 or 2,
A concrete pouring device for pouring concrete into the formwork,
The concrete pouring device includes:
A movable beam movably supported along the pair of fixed beams;
A plurality of concrete pouring hoses provided on the concrete pouring movable beam;
A concrete supply means for supplying concrete to the pouring hose;
An invert construction system comprising: A method for constructing an invert using the invert formwork manufacturing apparatus according to claim 1,
excavating and bedding the bottom of the tunnel;
A step of installing the invert form manufacturing apparatus;
A step of discharging the solidification material using the invert form manufacturing device to form a horizontal form and a vertical form;
A method for constructing an invert, comprising the steps of: pouring concrete into the space surrounded by the transverse formwork and the longitudinal formwork. A method for constructing an invert using the invert formwork manufacturing apparatus according to claim 2,
excavating and bedding the bottom of the tunnel;
A step of installing the invert form manufacturing apparatus;
scanning the tunnel floor surface using the 3D scanner;
calculating the difference between the shape of the tunnel deck surface and the design cross section;
Using the invert form manufacturing device, the solidification material is discharged according to the difference to form a transverse form and a longitudinal form;
A method for constructing an invert, comprising the steps of: pouring concrete into the space surrounded by the transverse formwork and the longitudinal formwork.

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