WO2023173797A1 - Tbm隧洞混凝土喷射的滑模施工***及方法 - Google Patents

Tbm隧洞混凝土喷射的滑模施工***及方法 Download PDF

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Publication number
WO2023173797A1
WO2023173797A1 PCT/CN2022/133513 CN2022133513W WO2023173797A1 WO 2023173797 A1 WO2023173797 A1 WO 2023173797A1 CN 2022133513 W CN2022133513 W CN 2022133513W WO 2023173797 A1 WO2023173797 A1 WO 2023173797A1
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concrete
sliding
spraying
formwork
tbm
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PCT/CN2022/133513
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English (en)
French (fr)
Inventor
姜守国
祁雪春
***
王宗敏
欧阳松
蔡忠伟
张秋
赵东波
蒋亚东
周泽沛
杨慧星
杨元红
金长文
李雷
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中国水利电力对外有限公司
中国铁建重工集团股份有限公司
中国水利水电第十四工程局有限公司
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Publication of WO2023173797A1 publication Critical patent/WO2023173797A1/zh

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    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21DSHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D11/00Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
    • E21D11/04Lining with building materials
    • E21D11/10Lining with building materials with concrete cast in situ; Shuttering also lost shutterings, e.g. made of blocks, of metal plates or other equipment adapted therefor
    • E21D11/105Transport or application of concrete specially adapted for the lining of tunnels or galleries ; Backfilling the space between main building element and the surrounding rock, e.g. with concrete
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21DSHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D11/00Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
    • E21D11/04Lining with building materials
    • E21D11/10Lining with building materials with concrete cast in situ; Shuttering also lost shutterings, e.g. made of blocks, of metal plates or other equipment adapted therefor
    • E21D11/102Removable shuttering; Bearing or supporting devices therefor

Definitions

  • the invention belongs to the technical field of sprayed concrete support for engineering tunnels, and in particular relates to a sliding form construction system and method for concrete spraying in TBM tunnels.
  • open TBM tunnels generally adopt support methods such as steel supports, steel bar rows, anchors, steel mesh, and shotcrete, and shotcrete is an important part of its support.
  • support methods such as steel supports, steel bar rows, anchors, steel mesh, and shotcrete
  • shotcrete is an important part of its support.
  • the shotcrete manipulator mounted on the TBM equipment.
  • the technology is very mature and the degree of mechanization is very high, there are also some problems that cannot be ignored in practice, which have always troubled technical workers. Mainly manifested in:
  • the concrete rebound rate is too high, generally reaching more than 30%, especially in vaults, water seepage, broken surrounding rocks and other places where the concrete rebound rate is even higher, which wastes more concrete materials. While increasing the project cost, it also increases the clean-up workload, which is not conducive to civilized construction management.
  • the present invention provides a sliding form construction system and method for concrete spraying of TBM tunnels.
  • This system combines the reality that the excavation speed of the open TBM tunnel does not match the support speed very well, and draws on the form spraying method.
  • Concrete and tunnel slip form technology is designed to provide a set of circumferential sliding formwork, which is mounted on the open TBM equipment and organically combined with the TBM's own shotcrete system to realize the slip form shotcrete function and make up for the shortcomings of the existing technology. , thereby achieving the purpose of improving the working environment, increasing support efficiency, enhancing support effects, improving support quality, saving project costs, facilitating parallel operations, reducing clean-up work, conducive to civilized construction, and matching TBM excavation efficiency.
  • a sliding form construction system for TBM tunnel concrete injection including a support system
  • the concrete spray truck connecting bridge of the support system is equipped with a translation system for driving the formwork system to move along the direction of tunnel excavation;
  • the translation system is supported and installed with a rotary sliding system for driving the formwork system to slide circumferentially along the tunnel;
  • the rotating sliding system is fixedly installed with a lifting and demoulding system for supporting and demoulding the formwork system;
  • the top of the lifting demoulding system is equipped with a formwork system
  • the concrete spraying truck connecting bridge is equipped with a concrete spraying system for spraying concrete.
  • the support system includes a TBM body, which is equipped with a concrete spray truck connecting bridge inside the TBM body; the TBM body is rollingly supported on the TBM track through a track wheel device.
  • the translation system includes a rack, which is fixed on the connecting bridge of the concrete spray truck supporting the system; the rack is engaged with the first gear for transmission, and the first gear is fixedly installed on the output shaft of the first hydraulic motor.
  • the first hydraulic motor is fixedly installed on the rotary sliding system, and a linear slide rail is installed on the connecting bridge of the concrete spraying truck.
  • the linear slide rail forms a sliding fit with the sliding seat on the rotary sliding system.
  • the rotary sliding system includes an annular beam, which is slidably supported on the concrete spray truck connecting bridge of the support system through a sliding seat; a ring gear is installed on the annular beam, and the ring gear is connected to the output of the second hydraulic motor.
  • the second gear meshing transmission on the shaft, the second hydraulic motor is fixedly installed on the rotating frame, and the rotating frame forms a sliding fit with the annular slide rail fixed on the annular beam; the rotating frame is equipped with a lifting and demoulding system .
  • the lifting and demoulding system includes a telescopic oil cylinder fixed on the rotating frame of the rotary sliding system.
  • the output shaft of the telescopic oil cylinder is equipped with a guide rod.
  • the guide rod is equipped with a compression spring; the template system is fixed on the guide rod. The top of the rod.
  • the formwork system includes an arc-shaped formwork installed at the end of a guide rod of the lifting and demoulding system, and an end flexible formwork is provided at the end of the arc-shaped formwork.
  • the concrete spraying system includes a manipulator bracket mounted on a rotating sliding system.
  • a manipulator is fixed on the manipulator bracket, and a concrete spray nozzle is mounted on the end of the manipulator.
  • the method of tunnel concrete spraying construction using the TBM tunnel concrete spraying slip form construction system includes the following steps:
  • Step 1 Production of sliding form construction system:
  • an existing TBM is used for addition or modification, and the implementation is entrusted to a professional manufacturer, it must match the TBM's concrete spraying system. If it is manufactured simultaneously with the TBM, it must be closely integrated with the shotcrete system. Consider common ring beams and rotating frames to achieve integration of slip form and shotcrete;
  • Step 2 Installation of sliding form construction system:
  • the concrete spraying machine is used to drive the concrete spray nozzle through the manipulator to spray concrete into the gap between the arc formwork and the excavated rock surface.
  • the process strictly follows the layering and step-by-step spraying of the formwork, and then the formwork system is rotated while the formwork is filled.
  • the process of spray concrete strictly follows the principles of layered uniform spraying and synchronous sliding; in this way, the concrete spraying construction is completed from bottom to top in a circular and gradual manner; when the construction reaches the vault capping position, considering the convenience of construction, spray concrete is directly used block; block;
  • Step 4 Rotation and sliding of the formwork system:
  • the initial sliding of the formwork system should be carried out slowly. During this process, the rotating sliding system, formwork system and related facilities should be fully inspected under load. Problems should be found and dealt with in a timely manner. Normal sliding can only be carried out after everything is normal. rise; the speed of the arch sections on both sides gradually slows down as the formwork system of the sliding form slides up, especially after it slides into the waist and the vault section, its speed should be strictly controlled, and continuous operation should be maintained as much as possible. Special personnel must observe the lifting.
  • the surface quality of the molded concrete is used to determine the appropriate sliding time and speed, which need to be determined based on comprehensive tests of concrete characteristics, feeding speed, ambient temperature, and demoulding strength;
  • Step 5 Defect elimination and curing of concrete:
  • Step 6 Decentralization and translation of the template system
  • the spray concrete starts from 270 degrees on both sides of the tunnel. Start; usually one concrete spraying system can be used to spray alternately from both sides of the tunnel.
  • two concrete spraying systems can be used to simultaneously spray from both sides of the tunnel; spraying concrete must be from bottom to top. It is carried out in layers. The first injection must be sprayed and filled in layers, and then the concrete is poured while sliding up 300mm. The concrete is squeezed onto the rock surface by rotating and sliding, so that a cycle of spraying is gradually completed from bottom to top. For concrete work, after demoulding, it is moved to the next warehouse number through the translation system. Only after this is completed step by step can the sliding form spray concrete work be continued.
  • the present invention designs a set of circumferential sliding formwork, mounts it on the open TBM equipment, and organically combines it with its shotcrete system to directly spray or spray concrete into the space between the formwork and the excavated rock surface.
  • the distance between the surface and the formwork is the thickness of the support.
  • Power equipment is relied on to make the formwork slide circumferentially, and concrete is sprayed while sliding to achieve rapid and timely support, thereby improving the working environment, improving support efficiency, and enhancing the support effect. , improve the quality of support, save project costs, facilitate parallel operations, reduce clean-up work, facilitate civilized construction, and match the efficiency of TBM excavation.
  • the invention has a simple structure, fully automatic control, and is easy to operate; after each cycle of construction is completed, it can be transferred to the next warehouse in a faster time.
  • the present invention uses a manipulator to directly spray concrete into the formwork.
  • the concrete can be fully utilized with almost no rebound, which greatly saves concrete costs, effectively controls dust, improves the working environment, reduces cleaning work, and is conducive to civilized construction.
  • the present invention can spray enough designed thickness at one time, the inner quality of the concrete is dense, the thickness and strength are reliable, the surface is smooth, and the quality is guaranteed.
  • the invention has a fast construction speed, can effectively improve the TBM efficiency, and matches the excavation efficiency, which is beneficial to improving the tunnel construction speed.
  • Figure 1 is a front view of the overall structure of the present invention.
  • Figure 2 is a view A-A in Figure 1 of the present invention.
  • Figure 3 is an enlarged view of part B in Figure 1 of the present invention.
  • Figure 4 is an enlarged view of part C in Figure 2 of the present invention.
  • support system 1 formwork system 2, rotation and sliding system 3, translation system 4, concrete injection system 5, lifting and demoulding system 6, tunnel 7, sprayed concrete section 8, excavated rock surface 9, spray concrete 10, Vault cap position 11;
  • Arc template 201 end flexible template 202;
  • the sliding form construction system for TBM tunnel concrete spraying includes a support system 1; the concrete spray truck connecting bridge 101 of the support system 1 is equipped with a translation system for driving the formwork system 2 to move along the tunnel excavation direction. 4;
  • the translation system 4 is supported and installed with a rotary sliding system 3 for driving the formwork system 2 to slide circumferentially along the tunnel;
  • the rotary sliding system 3 is fixedly installed with a rotary sliding system 3 for supporting and stripping the formwork system 2
  • Lifting and demoulding system 6; the top of the lifting and demoulding system 6 is equipped with a formwork system 2;
  • the concrete spraying truck connecting bridge 101 is equipped with a concrete spraying system 5 for spraying concrete.
  • the above-mentioned construction system By using the above-mentioned construction system, it is mounted on the open TBM equipment and organically combined with its shotcrete system to directly spray or spray concrete into the space between the formwork and the excavated rock surface, between the rock surface and the formwork The distance is the thickness of the support.
  • Power equipment is relied on to make the formwork slide circumferentially, while sliding and spraying concrete, to achieve rapid and timely support, thereby improving the working environment, improving support efficiency, enhancing the support effect, and improving the quality of the support. , save project costs, facilitate parallel operations, reduce cleaning work, facilitate civilized construction, and match the efficiency of TBM excavation.
  • the support system 1 includes a TBM body 102, which is equipped with a concrete spray truck connecting bridge 101 inside the TBM body 102; the TBM body 102 is rollingly supported on the TBM track 103 through the track wheel device 104.
  • the support system 1 is the skeleton of the sliding form device, and is also the support structure of the formwork, rotation, sliding, translation, lifting, and demoulding systems. It mainly uses the TBM shotcrete spraying truck connecting bridge 101 as a support.
  • the translation system 4 includes a rack 402, which is fixed on the concrete spray truck connecting bridge 101 of the support system 1; the rack 402 is engaged with the first gear 403 for transmission, and the first gear 403 is fixedly installed on the output shaft of the first hydraulic motor 404.
  • the first hydraulic motor 404 is fixedly installed on the rotating sliding system 3.
  • a linear slide rail 401 is installed on the connecting bridge 101 of the concrete spraying truck. The rail 401 forms a sliding fit with the sliding seat 306 on the rotating sliding system 3 .
  • the translation system 4 is a device that moves the formwork back and forth along the axis of the tunnel. It is installed on the connecting bridge 101 of the shotcrete truck.
  • the structure of the rotary sliding system 3 is the same as the rotary sliding system of the shotcrete manipulator inside the TBM;
  • the rotary sliding system 3 includes an annular beam 301, and the annular beam 301 is slidably supported on the support system through a sliding seat 306. 1 on the concrete spray truck connecting bridge 101;
  • a ring gear 305 is installed on the annular beam 301, the ring gear 305 meshes with the second gear 304 on the output shaft of the second hydraulic motor 303, and the second hydraulic motor 303 is fixedly installed on the rotating frame 302, which forms a sliding fit with the annular slide rail 307 fixed on the annular beam 301 through a slider;
  • the rotating frame 302 is equipped with a lifting and demoulding system 6.
  • the above-mentioned rotary sliding system 3 is the key to the circular rotation of the formwork.
  • the ring beam 301 and the ring gear are stereotyped products that can be customized according to the characteristics of the tunnel and can refer to the ring beam form of the shotcrete manipulator.
  • the ring gear is fixed on the ring beam 301;
  • the template is fixed on the rotating frame 302, and the rotating trolley provides power for the circular sliding of the template, and its gear matches the ring gear; the rotating trolley drives the rotating frame 302 to be driven by the hydraulic motor and reducer, and the gear ring gear rotates circularly along the annular beam.
  • Its rotation speed matches the speed of shotcrete, and the rotation moment needs to be selected through calculation. During calculation, sliding friction and concrete side pressure must be taken into consideration, and its safety factor must be fully considered.
  • the lifting and demoulding system 6 includes a telescopic oil cylinder 601 fixed on the rotating frame 302 of the rotary sliding system 3.
  • the output shaft of the telescopic oil cylinder 601 is equipped with a guide rod 603, and a pressing rod is installed on the guide rod 603.
  • Tight spring 602; the template system 2 is fixed on the top of the guide rod 603.
  • demoulding is achieved by a hydraulic telescopic cylinder.
  • the stroke and maximum thrust of the telescopic cylinder take into account factors such as concrete side pressure and friction.
  • the telescopic cylinder is installed between the sliding frame and the formwork, and is equipped with a guide device and a spring to adapt to changes in the sliding formwork conditions.
  • the sliding mold device uses front and rear walking devices, circumferential rotating devices, and sliding mold lifting devices to position, move, slide, and demold, thereby realizing the sliding mold function.
  • Concrete nozzles are provided at the front, rear and circumferential directions of the sliding form, and the position of the nozzles can be adjusted according to the spray mixing effect. If necessary, overlapping slip forms and overlapping brackets can be installed to increase the size of the formwork.
  • the template system 2 includes an arc-shaped template 201 installed at the end of the guide rod 603 of the lifting and demoulding system 6.
  • the end of the arc-shaped template 201 is provided with an end flexible template 202.
  • the formwork system 2 is a mold formed by shotcrete, which can be processed into an arc shape with steel plates according to the characteristics of the supporting section, and reinforced with shaped steel to ensure sufficient strength and stiffness.
  • the arc width of the formwork takes into account the initial setting time of concrete, sliding speed, demoulding strength and other factors, and is generally about 1 meter; the length of the formwork takes into account factors such as steel support spacing, TBM cycle progress, support speed, etc., and is generally 3 meters. Left and right are appropriate.
  • folding pages can be installed at the rear and lower parts of the formwork with a width of 300-500mm.
  • the length and width of the formwork can be appropriately increased to adapt to changes in relevant conditions during the support process.
  • an adjustable end flexible formwork is set at the front end of the formwork to adapt to changes in the supporting thickness of different surrounding rock to facilitate end sealing.
  • the formwork is divided into left and right pieces, which are fixed on the rotating frame and can slide synchronously or individually along the ring beam.
  • the concrete spraying system 5 includes a manipulator bracket 503 mounted on the rotary sliding system 3.
  • a manipulator 502 is fixed on the manipulator bracket 503, and a concrete spraying nozzle 501 is mounted on the end of the manipulator 502.
  • Indicators to meet the requirements of concrete transportation, spraying into warehousing, sliding, demoulding, etc.; secondly, the performance requirements of sprayed concrete equipment are strict, and high-performance concrete spraying equipment must be selected to improve construction efficiency; thirdly, the quality of operating technical workers The requirements are strict and skilled workers with multiple specialties must be selected to ensure the effective implementation of the process.
  • the method of tunnel concrete spraying construction using the TBM tunnel concrete spraying slip form construction system includes the following steps:
  • Step 1 Production of sliding form construction system:
  • an existing TBM is used for addition or modification, and a professional manufacturer is entrusted to implement it, it must match the TBM's concrete spraying system 5. If it is manufactured simultaneously with the TBM, it must be closely integrated with the shotcrete system. , consider the common ring beam and rotating frame to realize the integration of sliding form and shotcrete;
  • Step 2 Installation of sliding form construction system:
  • the concrete spraying machine is used to drive the concrete spraying nozzle 501 through the manipulator 502 to spray concrete into the gap between the arc formwork 201 and the excavated rock surface 9.
  • the process is strictly in accordance with the layering and step-by-step spraying of the formwork, and then the formwork is sprayed full.
  • the process strictly follows the principles of layered uniform spraying and synchronous sliding; in this way, the concrete spraying construction is completed in a bottom-up, cyclical and progressive manner; when the construction reaches the vault capping position 11, consider The construction is convenient and can be sealed directly with sprayed concrete;
  • Step 4 Rotation and sliding of template system 2:
  • the initial sliding of the formwork system 2 should be carried out slowly, and during this process, the rotating sliding system 3, the formwork system 2 and related facilities should be fully inspected under load, and problems should be found and dealt with in a timely manner until everything is normal.
  • Step 5 Defect elimination and curing of concrete:
  • Step 6 Decentralization and translation of template system 2;
  • the spray concrete is 270 meters from both sides of the tunnel. It starts from the position of the tunnel; usually, a shotcrete manipulator is used to spray the work alternately from both sides of the tunnel.
  • a shotcrete manipulator is used to spray the work alternately from both sides of the tunnel.
  • two manipulators are used to carry out the work simultaneously from both sides of the tunnel; the shotcrete must be shot from the bottom up. It is carried out in layers. The first spraying must be done in layers to spray and fill the formwork tightly. Then, the formwork is sprayed and poured while sliding up 300mm.
  • the concrete is squeezed onto the rock surface by rotating and sliding, so that a cycle is gradually completed from bottom to top.
  • the sliding form is moved to the next warehouse number through the translation system. Only after this step by step can the sliding form spray concrete operation be continued.

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  • Architecture (AREA)
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Abstract

公开了一种TBM隧洞混凝土喷射的滑模施工***,其包括用于对整体***进行支撑和搭载的支撑***(1);支撑***的喷砼车连接桥(101)上搭载有用于带动模板***(2)沿着隧洞掘进方向移动的平移***(4);平移***上支撑安装有用于驱动模板***沿着隧洞环向滑移的旋转滑动***(3);旋转滑动***上固定安装有用于对模板***进行支撑和脱膜的升降脱模***(6);升降脱模***的顶端安装有模板***;喷砼车连接桥上搭载有用于对混凝土进行喷射的混凝土喷射***(5)。还公开了采用该TBM隧洞混凝土喷射的滑模施工***进行隧洞混凝土喷射施工的方法,其能达到改善作业环境、提高支护效率、增强支护效果、提升支护质量、节约工程成本、方便平行作业、减少清理工作、与TBM开挖效率相匹配的目的。

Description

TBM隧洞混凝土喷射的滑模施工***及方法 技术领域
本发明属于工程隧洞喷射混凝土支护技术领域,尤其涉及TBM隧洞混凝土喷射的滑模施工***及方法。
背景技术
目前,敞开式TBM隧洞普遍采取钢支撑、钢筋排、锚杆、钢筋网以及喷混凝土等支护手段,而喷混凝土是其支护的重要环节。随着技术的进步,通常是依靠TBM设备上搭载的喷混凝土机械手来完成。虽然技术十分成熟,机械化程度也非常高,但实践中也存在一些不容忽视的问题,一直困扰着技术工作者。主要表现在:
1、喷混凝土作业时出现较大粉尘,工作环境较差;即便是采用先进的湿喷设备,也很难得到实质性改观,严重威胁职业健康。
2、喷混凝土作业时混凝土回弹率过高,一般情况下高达到30%以上,尤其是拱顶、渗水、破碎围岩等部位混凝土回弹率甚至更高,浪费了较多的混凝土材料,在加大了工程成本的同时,增加了清理工作量,不利于文明施工管理。
3、喷混凝土作业效率与TBM开挖速度不十分匹配,对于喷混凝土厚度较大时,需分多次、多层实施才能达到设计厚度,占用了较多的工序时间,制约TBM效率的发挥,对施工进度带来一定影响。
4、喷混凝土厚度不均匀、强度达标难、表面不平整、质量不稳定等是喷射混凝土作业的质量通病,严重时威胁隧洞安全使用。
发明内容
针对上述传统喷混凝土支护工艺存在的不足,本发明提供TBM隧洞混凝土喷射的滑模施工***及方法,此***结合敞开式TBM隧洞开挖速度与支护速度不十分匹配的实际,借鉴模喷混凝土和隧洞滑模技术,设计提供一套周向滑动模板,搭载到开敞式TBM设备上,与TBM自带的喷混凝土***有机结合起来,实现滑模喷射混凝土功能,弥补现有技术的不足,从而达到改善作业环境、提高支护效率、增强支护效果、提升支护质量、节约工程成本、方便平行作业、减少清理工作、有利文明施工、与TBM开挖效率相匹配的目的。
为了实现上述的技术特征,本发明的目的是这样实现的:TBM隧洞混凝土喷射的滑模施工***,包括支撑***;
所述支撑***的喷砼车连接桥上搭载有用于带动模板***沿着隧洞掘进方向移动的平移系 统;
所述平移***上支撑安装有用于驱动模板***沿着隧洞环向滑移的旋转滑动***;
所述旋转滑动***上固定安装有用于对模板***进行支撑和脱膜的升降脱模***;
所述升降脱模***的顶端安装有用于模板***;
所述喷砼车连接桥上搭载有用于对混凝土进行喷射的混凝土喷射***。
所述支撑***包括TBM本体,所述TBM本体的内部搭载有喷砼车连接桥;所述TBM本体通过轨道轮装置滚动支撑在TBM轨道上。
所述平移***包括齿条,所述齿条固定在支撑***的喷砼车连接桥上;所述齿条与第一齿轮啮合传动,所述第一齿轮固定安装在第一液压马达的输出轴上,所述第一液压马达固定安装在旋转滑动***上,所述喷砼车连接桥上安装有直线滑轨,所述直线滑轨与旋转滑动***上的滑移座构成滑动配合。
所述旋转滑动***包括环形梁,所述环形梁通过滑移座滑动支撑在支撑***的喷砼车连接桥上;所述环形梁上安装有齿圈,所述齿圈与第二液压马达输出轴上的第二齿轮啮合传动,所述第二液压马达固定安装在旋转框架上,所述旋转框架与固定在环形梁上的环形滑轨构成滑动配合;所述旋转框架上搭载升降脱模***。
所述旋转框架共有两组,并相对独立设置在环形梁上。
所述升降脱模***包括固定在旋转滑动***的旋转框架上的伸缩油缸,所述伸缩油缸的输出轴安装有导向杆,所述导向杆上套装有压紧弹簧;所述模板***固定在导向杆的顶端。
所述模板***包括安装在升降脱模***的导向杆末端的弧形模板,所述弧形模板的端头设置有端头柔性模板。
所述混凝土喷射***包括搭载在旋转滑动***上的机械手支架,所述机械手支架上固定有机械手,所述机械手的末端搭载有喷砼嘴。
采用TBM隧洞混凝土喷射的滑模施工***进行隧洞混凝土喷射施工的方法,包括以下步骤:
步骤一,滑模施工***制作:
根据整个滑模施工***的结构,如果利用已有TBM加装或改造,委托专业生产厂家实施,必须与TBM的混凝土喷射***相匹配,如果与TBM同步制造,则与喷混凝土***密切结合起来,考虑公用环形梁和旋转框架,实现滑模和喷射混凝土一体化;
步骤二,滑模施工***安装:
将制作好的滑模施工***的***部件与TBM进行组合安装,安装完成之后,无论是改造加装或是直接携带,均需专业厂家安装并调试,必须与TBM、喷混凝土机械手功能相匹配;
步骤三,喷混凝土施工:
利用混凝土喷射机通过机械手带动喷砼嘴将混凝土喷射到弧形模板与开挖岩面之间的缝隙内,其过程严格按照分层、分次逐步将模板喷满,尔后再边旋转模板***边喷灌混凝土,其过程严格执行分层均匀喷射、同步滑升的原则;如此自下而上、循环渐进的完成混凝土喷射施工;当施工至拱顶封顶部位时,考虑到施工方便,直接采取喷混凝土封堵;
步骤四,模板***的旋转滑升:
模板***的初次滑升要缓慢进行,并在此过程中,对旋转滑动***,模板***以及相关设施,在负载情况下,全面***检查,发现问题,及时处理,待一切正常后方可进行正常滑升;两边拱段随着滑模的模板***的滑升其速度逐渐减慢,尤其滑升进入腰部后和拱顶段后,其速度应严格控制,应尽量保持连续作业,须由专人观察脱模混凝土表面质量,以确定合适的滑升时间和滑升速度,这需要根据混凝土特性、供料速度、环境温度、脱模强度综合试验来确定;
步骤五,混凝土的消缺养护:
混凝土脱模后,对于混凝土表面平整度不足、顶部封顶不到位、各循环之间的错台现象,及时消缺,为了保证混凝土质量,采取喷水雾对脱模后的喷混凝土及时进行养护;
步骤六,模板***的下放、平移;
当模板***滑到拱顶封顶部位封堵完成并待强具备脱模强度后,启动升降脱模***的伸缩油缸,使模板***与混凝土脱离;尔后启动旋转滑动***将模板***旋转至两侧,再启动平移***向前移动至下一个仓号;如此循序往返,逐渐完成隧洞混凝土支护施工。
步骤三中喷混凝土施工过程中,对混凝土的水灰比、塌落度和速凝剂特性要求严格,必须在工艺实施前通过严格的实验来选取合适的混凝土指标,以满足混凝土运输、喷射入仓、滑动、脱模要求;
滑模施工过程中,直接将混凝土喷射到模板与开挖岩面之间的空间内,实现边喷射混凝土、边滑动模板、边脱模、边养护连续作业;
当设备就位、材料到位、人员到岗的准备工作就绪后,隧洞两侧的两组模板***随之就位,端头封堵完成,开始实施喷射混凝土,喷混凝土自隧洞两侧270度位置开始进行;通常采用一台混凝土喷射***从隧洞两侧交替喷射作业即可,当工程量大、强度要求高时,采用两台混凝土喷射***从隧洞两侧同步进行;喷射混凝土必须自下而上分层分次进行,首次喷射必 须分层喷射充灌密实后,再边滑升300mm、边喷灌混凝土,通过旋转滑动把混凝土挤压到岩面上,这样自下而上逐步完成一个循环的喷混凝土作业,脱模后再通过平移***移至下一个仓号作业,如此循序渐进的完后才能滑模喷混凝土连续作业。
本发明有如下有益效果:
1、本发明通过设计一套环向滑动模板,搭载到开敞式TBM设备上,与其喷混凝土***有机组合起来,直接将混凝土喷射或喷灌到模板与开挖岩面之间的空间内,岩面与模板之间的距离既为支护厚度,依靠动力设备使模板环向滑动,边滑动、边喷射混凝土,实现快速及时支护,从而达到改善作业环境、提高支护效率、增强支护效果、提升支护质量、节约工程成本、方便平行作业、减少清理工作、有利文明施工、与TBM开挖效率相匹配目的。
2、本发明结构简单,全自动控制,操作方便;每循环施工完毕,能在较快的时间内转移至下一个仓位。
3、本发明利用机械手直接将混凝土喷灌到模板内,混凝土能够充分利用,几乎没有回弹,大大节约混凝土成本,并有效控制粉尘,改善作业环境,减少清理工作,有利文明施工。
4、本发明可一次喷够设计厚度,混凝土内在质量密实,厚度、强度可靠,表面平整,质量有保证。
5、本发明施工速度快,可有效提高TBM效率,并与开挖效率相匹配,有利于隧洞施工速度的提高。
附图说明
下面结合附图和实施例对本发明作进一步说明。
图1为本发明的整体结构主视图。
图2为本发明的图1中A-A视图。
图3为本发明的图1中B局部放大图。
图4为本发明的图2中C局部放大图。
图中:支撑***1、模板***2、旋转滑动***3、平移***4、混凝土喷射***5、升降脱模***6、隧洞7、已喷砼段8、开挖岩面9、喷灌混凝土10、拱顶封顶部位11;
喷砼车连接桥101、TBM本体102、TBM轨道103、轨道轮装置104;
弧形模板201、端头柔性模板202;
环形梁301、旋转框架302、第二液压马达303、第二齿轮304、齿圈305、滑移座306、环形滑轨307;
直线滑轨401、齿条402、第一齿轮403、第一液压马达404;
喷砼嘴501、机械手502、机械手支架503;
伸缩油缸601、压紧弹簧602、导向杆603。
具体实施方式
下面结合附图对本发明的实施方式做进一步的说明。
实施例1:
参见图1-4,TBM隧洞混凝土喷射的滑模施工***,包括支撑***1;所述支撑***1的喷砼车连接桥101上搭载有用于带动模板***2沿着隧洞掘进方向移动的平移***4;所述平移***4上支撑安装有用于驱动模板***2沿着隧洞环向滑移的旋转滑动***3;所述旋转滑动***3上固定安装有用于对模板***2进行支撑和脱膜的升降脱模***6;所述升降脱模***6的顶端安装有用于模板***2;所述喷砼车连接桥101上搭载有用于对混凝土进行喷射的混凝土喷射***5。通过采用上述的施工***,其搭载到开敞式TBM设备上,与其喷混凝土***有机组合起来,直接将混凝土喷射或喷灌到模板与开挖岩面之间的空间内,岩面与模板之间的距离既为支护厚度,依靠动力设备使模板环向滑动,边滑动、边喷射混凝土,实现快速及时支护,从而达到改善作业环境、提高支护效率、增强支护效果、提升支护质量、节约工程成本、方便平行作业、减少清理工作、有利文明施工、与TBM开挖效率相匹配目的。
进一步的,所述支撑***1包括TBM本体102,所述TBM本体102的内部搭载有喷砼车连接桥101;所述TBM本体102通过轨道轮装置104滚动支撑在TBM轨道103上。
其中支撑***1是该滑模装置的骨架,也是模板、旋转、滑动、平移、升降、脱模***的支撑构架,其主要利用TBM上喷混凝土喷砼车连接桥101作为支撑。
进一步的,所述平移***4包括齿条402,所述齿条402固定在支撑***1的喷砼车连接桥101上;所述齿条402与第一齿轮403啮合传动,所述第一齿轮403固定安装在第一液压马达404的输出轴上,所述第一液压马达404固定安装在旋转滑动***3上,所述喷砼车连接桥101上安装有直线滑轨401,所述直线滑轨401与旋转滑动***3上的滑移座306构成滑动配合。其中平移***4是模板沿隧洞轴线前后行走的装置,安装在喷砼车连接桥101上,可利用喷混凝土机械手的平移齿条,通过液压马达、减速机驱动、齿轮齿条传动完成旋转框架的前后移动,实现混凝土喷射位置在隧洞轴线方向上的定位和行走,其行走速度与喷混凝土机械手相匹配,驱动力需经过计算得到。
进一步的,所述旋转滑动***3的结构与TBM内部的喷混凝土机械手的旋转滑动系 统相同;所述旋转滑动***3包括环形梁301,所述环形梁301通过滑移座306滑动支撑在支撑***1的喷砼车连接桥101上;所述环形梁301上安装有齿圈305,所述齿圈305与第二液压马达303输出轴上的第二齿轮304啮合传动,所述第二液压马达303固定安装在旋转框架302上,所述旋转框架302通过滑块与固定在环形梁301上的环形滑轨307构成滑动配合;所述旋转框架302上搭载升降脱模***6。上述的旋转滑动***3是模板环向旋转的关键,环形梁301、齿圈为定型产品,可根据隧洞特征定制,并可参照喷混凝土机械手的环梁形式,齿圈固定在环形梁301上;模板固定在在旋转框架302上,旋转小车为模板环向滑动提供动力,其齿轮与齿圈相匹配;旋转小车带动旋转框架302通过液压马达、减速机驱动、齿轮齿圈沿环形梁环向旋转,实现边滑动、边喷混凝土功能。其旋转速度与喷混凝土速度相匹配,旋转力矩需通过计算选取,计算时要统筹考虑滑动摩阻力、混凝土侧压力,并充分考虑其安全系数。
进一步的,所述旋转框架302共有两组,并相对独立设置在环形梁301上。通过采用两组在一定程度上提高了施工效率。
进一步的,所述升降脱模***6包括固定在旋转滑动***3的旋转框架302上的伸缩油缸601,所述伸缩油缸601的输出轴安装有导向杆603,所述导向杆603上套装有压紧弹簧602;所述模板***2固定在导向杆603的顶端。当拱顶混凝土封堵完成并待强后,既可以脱模;脱模通过液压伸缩油缸来实现,伸缩油缸的行程、最大推力综合考虑混凝土侧压力、摩阻力等因素。伸缩油缸安装在滑动框架与模板之间,并设置有导向装置及弹簧,以适应滑模工况的变化。
滑模装置通过前后行走装置、环向旋转装置、滑模升降装置来定位、移动、滑动、脱模,从而实现滑模功能。在滑模前后和环向均设置有混凝土喷嘴,可根据喷混效果调整喷嘴位置。必要时,可安装搭接滑模和搭接支架,以加大模板尺寸。
进一步的,所述模板***2包括安装在升降脱模***6的导向杆603末端的弧形模板201,所述弧形模板201的端头设置有端头柔性模板202。所述模板***2是喷混凝土成型的模具,可根据支护断面特征用钢板加工成弧形,并用型钢加肋,保证足够的强度与刚度。模板弧形宽度综合考虑其混凝土初凝时间、滑升速度、脱模强度等因素,一般1米左右为宜;模板长度综合考虑钢支撑间距、TBM循环进度、支护速度等因素,一般3米左右为宜。为了增加模板的实用性,可在模板后部、下部加装折页,宽度300-500mm,适当增加模板的长度与宽度,以适应支护过程中相关情况的变化。同时,在模板前端头设置可调节端头柔性模板,以适应不同围岩支护厚度的变化,以方便端头封堵。模板分为左、右侧各一块, 固定在旋转框架上,可沿环梁环形同步或单独滑动。
进一步的,所述混凝土喷射***5包括搭载在旋转滑动***3上的机械手支架503,所述机械手支架503上固定有机械手502,所述机械手502的末端搭载有喷砼嘴501。滑模喷混凝土支护施工工艺的要点有三方面:一是对混凝土的特性:水灰比、塌落度,尤其是速凝剂要求严格,必须在工艺实施前通过严格的实验来选取合适的混凝土指标,以满足混凝土运输、喷射入仓、滑动、脱模等要求;二是对喷混凝土设备的性能要求严格,必须选用高性能混凝土喷射设备,以提高施工效率;三是对操作技术工人的素质要求严格,必须选用一专多能的技术工人,以保证工艺的有效实施。
实施例2:
采用TBM隧洞混凝土喷射的滑模施工***进行隧洞混凝土喷射施工的方法,包括以下步骤:
步骤一,滑模施工***制作:
根据整个滑模施工***的结构,如果利用已有TBM加装或改造,委托专业生产厂家实施,必须与TBM的混凝土喷射***5相匹配,如果与TBM同步制造,则与喷混凝土***密切结合起来,考虑公用环形梁和旋转框架,实现滑模和喷射混凝土一体化;
步骤二,滑模施工***安装:
将制作好的滑模施工***的***部件与TBM进行组合安装,安装完成之后,无论是改造加装或是直接携带,均需专业厂家安装并调试,必须与TBM、喷混凝土机械手功能相匹配;
步骤三,喷混凝土施工:
利用混凝土喷射机通过机械手502带动喷砼嘴501将混凝土喷射到弧形模板201与开挖岩面9之间的缝隙内,其过程严格按照分层、分次逐步将模板喷满,尔后再边旋转模板***2边喷灌混凝土10,其过程严格执行分层均匀喷射、同步滑升的原则;如此自下而上、循环渐进的完成混凝土喷射施工;当施工至拱顶封顶部位11时,考虑到施工方便,直接采取喷混凝土封堵;
步骤四,模板***2的旋转滑升:
模板***2的初次滑升要缓慢进行,并在此过程中,对旋转滑动***3,模板***2以及相关设施,在负载情况下,全面***检查,发现问题,及时处理,待一切正常后方可进行正常滑升;两边拱段随着滑模的模板***2的滑升其速度逐渐减慢,尤其滑升进入腰部后和拱顶段后,其速度应严格控制,应尽量保持连续作业,须由专人观察脱模混凝土表面质量,以确定合适的滑升时间和滑升速度,这需要根据混凝土特性、供料速度、环境温度、脱模强度综 合试验来确定;
步骤五,混凝土的消缺养护:
混凝土脱模后,对于混凝土表面平整度不足、顶部封顶不到位、各循环之间的错台现象,及时消缺,为了保证混凝土质量,采取喷水雾对脱模后的喷混凝土及时进行养护;
步骤六,模板***2的下放、平移;
当模板***2滑到拱顶封顶部位11封堵完成并待强具备脱模强度后,启动升降脱模***6的伸缩油缸,使模板***2与混凝土脱离;尔后启动旋转滑动***3将模板***2旋转至两侧,再启动平移***4向前移动至下一个仓号;如此循序往返,逐渐完成隧洞混凝土支护施工。
步骤三中喷混凝土施工过程中,对混凝土的水灰比、塌落度和速凝剂特性要求严格,必须在工艺实施前通过严格的实验来选取合适的混凝土指标,以满足混凝土运输、喷射入仓、滑动、脱模要求;
滑模施工过程中,直接将混凝土喷射到模板与开挖岩面之间的空间内,实现边喷射混凝土、边滑动模板、边脱模、边养护连续作业;
当设备就位、材料到位、人员到岗的准备工作就绪后,隧洞两侧的两组模板***2随之就位,端头封堵完成位,开始实施喷射混凝土,喷混凝土自隧洞两侧270度位置开始进行;通常采用一台喷混凝土机械手从隧洞两侧交替喷射作业即可,当工程量大、强度要求高时,采用两台机械手从隧洞两侧同步进行;喷射混凝土必须自下而上分层分次进行,首次喷射必须分层将模板喷射充灌密实后,再边滑升300mm、边喷灌混凝土,通过旋转滑动把混凝土挤压到岩面上,这样自下而上逐步完成一个循环的喷混凝土作业,脱模后再通过平移***将滑模移至下一个仓号作业,如此循序渐进的完后才能滑模喷混凝土连续作业。

Claims (9)

  1. TBM隧洞混凝土喷射的滑模施工***,其特征在于:包括支撑***(1);
    所述支撑***(1)的喷砼车连接桥(101)上搭载有用于带动模板***(2)沿着隧洞掘进方向移动的平移***(4);
    所述平移***(4)上支撑安装有用于驱动模板***(2)沿着隧洞环向滑移的旋转滑动***(3);
    所述旋转滑动***(3)上固定安装有用于对模板***(2)进行支撑和脱膜的升降脱模***(6);
    所述升降脱模***(6)的顶端安装有用于模板***(2);
    所述喷砼车连接桥(101)上搭载有用于对混凝土进行喷射的混凝土喷射***(5)。
  2. 根据权利要求1所述TBM隧洞混凝土喷射的滑模施工***,其特征在于,所述支撑***(1)包括TBM本体(102),所述TBM本体(102)的内部搭载有喷砼车连接桥(101);所述TBM本体(102)通过轨道轮装置(104)滚动支撑在TBM轨道(103)上。
  3. 根据权利要求1所述TBM隧洞混凝土喷射的滑模施工***,其特征在于,所述平移***(4)包括齿条(402),所述齿条(402)固定在支撑***(1)的喷砼车连接桥(101)上;所述齿条(402)与第一齿轮(403)啮合传动,所述第一齿轮(403)固定安装在第一液压马达(404)的输出轴上,所述第一液压马达(404)固定安装在旋转滑动***(3)上,所述喷砼车连接桥(101)上安装有直线滑轨(401),所述直线滑轨(401)与旋转滑动***(3)上的滑移座(306)构成滑动配合。
  4. 根据权利要求1所述TBM隧洞混凝土喷射的滑模施工***,其特征在于,所述旋转滑动***(3)包括环形梁(301),所述环形梁(301)通过滑移座(306)滑动支撑在支撑***(1)的喷砼车连接桥(101)上;所述环形梁(301)上安装有齿圈(305),所述齿圈(305)与第二液压马达(303)输出轴上的第二齿轮(304)啮合传动,所述第二液压马达(303)固定安装在旋转框架(302)上,所述旋转框架(302)与固定在环形梁(301)上的环形滑轨(307)构成滑动配合;所述旋转框架(302)上搭载升降脱模***(6)。
  5. 根据权利要求1所述TBM隧洞混凝土喷射的滑模施工***,其特征在于,所述升降脱模***(6)包括固定在旋转滑动***(3)的旋转框架(302)上的伸缩油缸(601),所述伸缩油缸(601)的输出轴安装有导向杆(603),所述导向杆(603)上套装有压紧弹簧(602);所述模板***(2)固定在导向杆(603)的顶端。
  6. 根据权利要求1或6所述TBM隧洞混凝土喷射的滑模施工***,其特征在于,所述模板***(2)包括安装在升降脱模***(6)的导向杆(603)末端的弧形模板(201),所述弧 形模板(201)的端头设置有端头柔性模板(202)。
  7. 根据权利要求1所述TBM隧洞混凝土喷射的滑模施工***,其特征在于,所述混凝土喷射***(5)包括搭载在旋转滑动***(3)上的机械手支架(503),所述机械手支架(503)上固定有机械手(502),所述机械手(502)的末端搭载有喷砼嘴(501)。
  8. 采用权利要求1-8任意一项所述TBM隧洞混凝土喷射的滑模施工***进行隧洞混凝土喷射施工的方法,其特征在于,包括以下步骤:
    步骤一,滑模施工***制作:
    根据整个滑模施工***的结构,如果利用已有TBM加装或改造,委托专业生产厂家实施,必须与TBM的混凝土喷射***(5)相匹配,如果与TBM同步制造,则与喷混凝土***密切结合起来,考虑公用环形梁和旋转框架,实现滑模和喷射混凝土一体化;
    步骤二,滑模施工***安装:
    将制作好的滑模施工***的***部件与TBM进行组合安装,安装完成之后,无论是改造加装或是直接携带,均需专业厂家安装并调试,必须与TBM、喷混凝土机械手功能相匹配;
    步骤三,喷混凝土施工:
    利用混凝土喷射机通过机械手(502)带动喷砼嘴(501)将混凝土喷射到弧形模板(201)与开挖岩面(9)之间的缝隙内,其过程严格按照分层、分次逐步将模板喷满,尔后再边旋转模板***(2)边喷灌混凝土(10),其过程严格执行分层均匀喷射、同步滑升的原则;如此自下而上、循环渐进的完成混凝土喷射施工;当施工至拱顶封顶部位(11)时,考虑到施工方便,直接采取喷混凝土封堵;
    步骤四,模板***(2)的旋转滑升:
    模板***(2)的初次滑升要缓慢进行,并在此过程中,对旋转滑动***(3),模板***(2)以及相关设施,在负载情况下,全面***检查,发现问题,及时处理,待一切正常后方可进行正常滑升;两边拱段随着滑模的模板***(2)的滑升其速度逐渐减慢,尤其滑升进入腰部后和拱顶段后,其速度应严格控制,应尽量保持连续作业,须由专人观察脱模混凝土表面质量,以确定合适的滑升时间和滑升速度,这需要根据混凝土特性、供料速度、环境温度、脱模强度综合试验来确定;
    步骤五,混凝土的消缺养护:
    混凝土脱模后,对于混凝土表面平整度不足、顶部封顶不到位、各循环之间的错台现象,及时消缺,为了保证混凝土质量,采取喷水雾对脱模后的喷混凝土及时进行养护;
    步骤六,模板***(2)的下放、平移;
    当模板***(2)滑到拱顶封顶部位(11)封堵完成并待强具备脱模强度后,启动升降脱模***(6)的伸缩油缸(601),使模板***(2)与混凝土脱离;尔后启动旋转滑动***(3)将模板***(2)旋转至两侧,再启动平移***(4)向前移动至下一个仓号;如此循序往返,逐渐完成隧洞混凝土支护施工。
  9. 根据权利要求9所述TBM隧洞混凝土喷射的滑模施工***进行隧洞混凝土喷射施工的方法,其特征在于:
    步骤三中喷混凝土施工过程中,对混凝土的水灰比、塌落度和速凝剂特性要求严格,必须在工艺实施前通过严格的实验来选取合适的混凝土指标,以满足混凝土运输、喷射入仓、滑动、脱模要求;
    滑模施工过程中,直接将混凝土喷射到模板与开挖岩面之间的空间内,实现边喷射混凝土、边滑动模板、边脱模、边养护连续作业;
    当设备就位、材料到位、人员到岗的准备工作就绪后,隧洞两侧的两组模板***(2)随之就位,端头封堵完成,开始实施喷射混凝土,喷混凝土自隧洞两侧270度位置开始进行;通常采用一台混凝土喷射***(5)从隧洞两侧交替喷射作业即可,当工程量大、强度要求高时,采用两台混凝土喷射***(5)从隧洞两侧同步进行;喷射混凝土必须自下而上分层分次进行,首次喷射必须分层喷射充灌密实后,再边滑升300mm、边喷灌混凝土,通过旋转滑动把混凝土挤压到岩面上,这样自下而上逐步完成一个循环的喷混凝土作业,脱模后再通过平移***(4)移至下一个仓号作业,如此循序渐进的完后才能滑模喷混凝土连续作业。
PCT/CN2022/133513 2022-03-16 2022-11-22 Tbm隧洞混凝土喷射的滑模施工***及方法 WO2023173797A1 (zh)

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