An Existing Tunnel Repair Structure and Construction Method

Abstract

This invention provides a structure and construction method for repairing existing tunnels. The existing tunnel repair structure includes a corrugated plate assembly, anchors, rail guide plates, and a reinforcement layer. The corrugated plate assembly is formed by splicing stainless steel corrugated plates circumferentially along the existing tunnel, with inward flanges on both sides of each stainless steel corrugated plate. The ends of adjacent stainless steel corrugated plates are fixed together by bridging components. In this invention, the assembled corrugated steel assembly is connected to the track bed as a single ring structure via anchors and rail guide plates. It is then fixed to the existing tunnel as a whole by fasteners. Micro-expansion high-strength cement mortar is injected into the space formed between the assembled structure and the inner wall of the existing tunnel. After solidification, the reinforcement layer formed becomes an integral part of the stainless steel assembled structure and the inner wall of the existing tunnel, forming a common load-bearing structure, thereby achieving the purpose of repairing and reinforcing existing tunnels. This method is suitable for intermittent or continuous repair of tunnels such as subways and railways, and has high repair and reinforcement efficiency.

Description

Technical Field

[0001] This invention belongs to the field of tunnel repair technology, and specifically relates to an existing tunnel repair structure and construction method. Background Technology

[0002] Urban rail transit mainly includes subways, light rail, monorails, new transportation systems, and maglev transportation. Tunnels in urban rail transit are mostly designed and constructed using shield tunneling structures, which are assembled entirely from precast segments fixed with bolts. They form a multi-ring structure in the soil at a depth of about 20-50 meters underground, with a pressure lower than that of the external soil (including cement slurry). Thus, the soil and slurry around the tunnel become the load support and the carrier that ensures the stability of the tunnel structure. Even a small amount of overloading, unloading, or displacement can cause deformation of the tunnel structure. Severe deformation can affect the safety clearance of vehicles inside the tunnel and directly endanger safe operation. With the increase in the total mileage of railway construction, tunnel defects are inevitable, which will lead to a large amount of tunnel repair projects.

[0003] Currently, the main repair and reinforcement methods for existing tunnels, both domestically and internationally, are fiber-reinforced composite reinforcement and steel plate reinforcement. Fiber-reinforced composite reinforcement faces the challenge of the adhesive not fully curing in a short time, which seriously affects the effectiveness of tunnel structural repair and reinforcement. Steel plate reinforcement, on the other hand, faces difficulties such as the excessive weight of the steel plates, the need for specialized lifting equipment for long-distance access to and from the site, excessive time consumption, numerous welds, large fluctuations in welding quality, and high reinforcement costs.

[0004] How to design a repair structure and construction method for existing tunnels, and how to increase the repair efficiency of existing tunnels, are urgent problems to be solved. Summary of the Invention

[0005] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide an existing tunnel repair structure and construction method to solve the problems of difficulty and low efficiency in the repair of existing tunnels in the prior art.

[0006] To achieve the above objectives, the present invention provides an existing tunnel repair structure, including a corrugated plate assembly, a foundation, a track rail strip, and a reinforcement layer;

[0007] The corrugated plate assembly is formed by splicing stainless steel corrugated plates circumferentially along the existing tunnel. Both sides of the stainless steel corrugated plates are provided with inward flanges. Adjacent stainless steel corrugated plates are fixed together by bridging components. The bridging components include bridging plates lined between the ends of adjacent stainless steel corrugated plates. The bridging plates are fixed to the end crests of the stainless steel corrugated plates by bolts. The bridging plates are fixed to the end troughs of the stainless steel corrugated plates and the inner wall of the existing tunnel by fasteners, forming a grouting space between the stainless steel corrugated plates and the inner wall of the existing tunnel.

[0008] The upper end of the anchor is circumferentially connected to the lower end of the corrugated plate assembly along the tunnel. The connection structure between the anchor and the corrugated plate assembly is the same as the connection structure between the adjacent stainless steel corrugated plate.

[0009] The track-passing strip crosses the existing track and is fixed to the lower end of the base;

[0010] The reinforcement layer is formed by the solidification of micro-expansion high-strength cement mortar injected into the injection space.

[0011] This technical solution involves installing anchors on both sides of the existing tunnel track bed, and assembling a corrugated steel component structure using stainless steel corrugated plates above the anchors. The anchors on both sides of the existing track bed are then fixed using rail guides. The corrugated steel components, anchors, rail guides, and track guides are connected to the track bed to form a unified structure. Fasteners are then used to secure the stainless steel corrugated plates and anchors to the existing tunnel wall. Finally, micro-expansion high-strength cement mortar is injected into the grouting space between the stainless steel corrugated plates and the existing tunnel wall. After solidification, a reinforcement layer is formed, thus repairing the existing tunnel wall. The corrugated steel components, anchors, and rail guides... The strips and track bed are connected as an integral ring structure. This structure is fixed to the existing tunnel wall with fasteners, and micro-expansion high-strength cement mortar is poured into the gap between the structure and the existing tunnel wall. After curing, it forms a common load-bearing structure with the existing tunnel, thereby achieving the purpose of repairing and reinforcing the existing tunnel. It is suitable for intermittent or continuous repair of tunnels such as subways and railways. The integral ring structure assembled with stainless steel corrugated plates is a modular structure, which can achieve rapid repair and reinforcement of existing tunnels, while significantly reducing construction time and difficulty, and increasing the repair efficiency of existing tunnels.

[0012] In one embodiment of the present invention, the inner flange includes two types: flange inner flange and reinforcing rib inner flange, wherein the center position of the flange inner flange is provided with evenly distributed axial connecting holes along the plate direction of the stainless steel corrugated plate.

[0013] By adopting this technical solution, two types of flanges are set up. Stainless steel corrugated plates with flange inward flanges and reinforcing rib inward flanges can be selected according to the actual longitudinal repair width of the tunnel. The stainless steel corrugated plates with flange inward flanges can be connected along the longitudinal direction of the tunnel through the axial connection holes on them and bolts, so as to adapt to the longitudinal repair width required by different tunnels.

[0014] In one embodiment of the present invention, the bridging component further includes a waterproof gasket, which is pressed between the bridging plate and the body to be connected, wherein the body to be connected includes a stainless steel corrugated plate and a foot.

[0015] By adopting this technical solution, the sealing at the connection points of adjacent stainless steel corrugated plates and the connection points between the stainless steel corrugated plates and the foundation is increased, preventing leakage of the repaired structure and avoiding overflow of micro-expansion high-strength cement mortar during subsequent grouting.

[0016] In one embodiment of the present invention, a first anchoring hole for fasteners is provided at the trough position of the end of the stainless steel corrugated plate, and a first bolting hole for bolts is provided at the crest position of the end of the stainless steel corrugated plate.

[0017] By adopting this technical solution, the trough position of the stainless steel corrugated plate is more closely fitted to the inner wall of the tunnel. The first anchor hole is opened at the trough position to increase the stability of the connection between the stainless steel corrugated plate and the existing inner wall of the tunnel with fasteners. The crest position of the stainless steel corrugated plate will have a certain distance from the inner wall of the tunnel, which facilitates the installation of bolts and the connection between adjacent stainless steel corrugated plates, and can ensure that the stainless steel corrugated plate can form a grouting space with the inner wall of the tunnel.

[0018] In one embodiment of the present invention, the bridging plate is a corrugated plate with the same waveform as the stainless steel corrugated plate and the top of the footplate, and through holes are provided at both the crest and trough of the bridging plate, and the through holes are waist-shaped holes.

[0019] By adopting this technical solution, we can ensure that the bridging plate can fit snugly against the stainless steel corrugated plate and the foot end, increasing the interconnection area. After connecting with bolts, we can ensure the stability of the connection. The waist-shaped through hole is set to accommodate the position of the bolt, which can adjust the assembly deviation and reduce the difficulty of connection.

[0020] In one embodiment of the present invention, the foot is a thermoformed mesh frame structure, a second anchor hole for fastener is provided at the upper trough of the foot, and a second bolt hole for bolt is provided at the upper crest of the foot, both the second anchor hole and the second bolt hole are strip-shaped holes.

[0021] By adopting this technical solution: setting the upper side of the base as a thermoformed mesh frame structure to increase the strength of the overall structure; setting the second anchor hole and the second bolt hole to accommodate fasteners and bolts respectively, and setting the second anchor hole and the second bolt hole as strip holes to accommodate the position of fasteners and bolts, assembly deviations can be adjusted and the difficulty of connection can be reduced.

[0022] In one embodiment of the present invention, the lower end of the foot is fixed to one leg of the corner connector by bolts, and the other leg of the corner connector overlaps the upper side of the end of the track plate and is fixed by bolts.

[0023] By adopting this technical solution, corner joints are set as intermediate connecting parts to achieve the connection between the bottom of the base and the end of the track strip.

[0024] In one embodiment of the present invention, both ends of the track strip are provided with a third bolting hole for bolt engagement, and the third bolting hole is an oblong hole.

[0025] By adopting this technical solution—providing the bolt installation position through the third bolt hole and setting the third bolt hole as an oblong hole to accommodate the bolt position—the assembly plug can be adjusted, reducing the difficulty of connection.

[0026] A construction method for repairing existing tunnel structures, characterized by the following steps:

[0027] S1. Preparation: Secure the bolts and suitable waterproof gaskets to the first bolting hole at the end of the stainless steel corrugated plate and the second bolting hole at the upper end of the anchor plate using snap rings.

[0028] S2. Initial Installation: Place anchors on both sides of the existing track bed foundation. Starting from the top of the anchor on either side, place the first stainless steel corrugated plate. Ensure that the joint between the stainless steel corrugated plate and the anchor is on the same arc. Then, place a bridging plate inside the joint between the stainless steel corrugated plate and the anchor, and fit the bridging plate onto the bolts fixing the joint between the stainless steel corrugated plate and the anchor through the through hole. Tighten the bolts to press the bridging plate onto the anti-seepage gasket and complete the fixing of the joint between the stainless steel corrugated plate and the anchor. Use the same method to connect adjacent stainless steel corrugated plates along the circumference of the existing tunnel. Finally, fix the last stainless steel corrugated plate to the top of the anchor on the other side.

[0029] S3. Fixed installation: The anchor bolts, which serve as fasteners, are driven into the existing tunnel wall by passing through the remaining unused through holes on the bridge plate, the anti-seepage gasket, and the first anchor hole on the stainless steel corrugated plate in sequence from the inside to the outside, thus completing the fixing of the stainless steel corrugated plate to the existing tunnel wall.

[0030] S4. Integrated Connection: Lay a rail strip plate on the existing track, and fix one leg of the corner joint at the end of the rail strip plate with a bolt through the third bolt hole. Then fix the other leg of the corner joint to the lower end of the anchor with a bolt. The anchor bolt, which serves as a fastener, is driven into the inner wall of the existing tunnel by passing through the remaining unused bolt holes on the bridge plate, the anti-seepage gasket, and the second anchor hole on the anchor from the inside out, thus completing the fixation of the anchor to the inner wall of the existing tunnel.

[0031] S5. Grouting: Grouting holes and overflow holes are opened on the installed upper and middle stainless steel corrugated plates. Micro-expansion high-strength cement mortar is injected into the grouting space formed between the stainless steel corrugated plates and the existing tunnel inner wall through the grouting holes. The grout flows by gravity and the grouting of the entire ring is completed in one go. Wait for the micro-expansion high-strength cement mortar to solidify into a reinforcement layer to complete the reinforcement construction.

[0032] As described above, the existing tunnel repair structure and construction method of the present invention have the following beneficial effects: 1) The assembled corrugated steel assembly is connected to the track bed through anchors and rail strips to form an integral ring structure, and then fixed to the existing tunnel as a whole by fasteners. Micro-expansion high-strength cement mortar is injected into the grouting space formed between the structure and the inner wall of the existing tunnel. After the micro-expansion high-strength cement mortar solidifies, the structure and the existing tunnel structure form a common load-bearing structure, thereby achieving the purpose of repairing and reinforcing the existing tunnel. This common load-bearing structure has high repair and reinforcement efficiency; 2) The corrugated steel assembly is connected by stainless steel corrugated plates and bridging parts. The stainless steel corrugated plates themselves have a long service life, and each piece is stainless steel. Steel corrugated plates occupy a small area, are easy to transport, and have low cost. They can also be quickly connected after being transported to the tunnel repair location, resulting in high construction efficiency. 3) Using stainless steel corrugated plate assemblies with flanged inward or reinforced inward, they are suitable for continuous or intermittent repair of existing tunnels. 4) By fully utilizing the characteristics of corrugated plates, a grouting space is formed between the corrugated plates and the existing tunnel wall. The bolt holes and anchor holes are distinguished. The anchor holes, together with fasteners, can achieve a double effect of fastening the connection between adjacent corrugated plates and fixing the corrugated plates to the existing tunnel wall. This increases the connection strength between adjacent corrugated plates, increases the stability of the overall structure, and reduces the number of anchor bolts used. The promotion and application of this technology has good economic and social benefits. Attached Figure Description

[0033] Figure 1 This is a three-dimensional schematic diagram of the present invention.

[0034] Figure 2 This is a side view of the stainless steel corrugated plate of the present invention.

[0035] Figure 3 This is a cross-sectional view of the stainless steel corrugated plate of the present invention.

[0036] Figure 4 This is a schematic diagram of the stainless steel corrugated plate end connection of the present invention.

[0037] Figure 5 This is a cross-sectional view of the bridging plate of the present invention.

[0038] Figure 6 This is a side view of the bridging plate of the present invention.

[0039] Figure 7 This is the front view of the base of the present invention.

[0040] Figure 8 This is a side view of the base of the present invention.

[0041] Figure 9 yes Figure 7 Cross-sectional view along the AA direction.

[0042] Figure 10 This is a cross-sectional view of the corner connector of the present invention.

[0043] Figure 11 This is a top view of the track-passing strip of the present invention.

[0044] In the diagram: 1. Corrugated plate assembly; 11. Stainless steel corrugated plate; 111. First anchor hole; 112. First bolt hole; 2. Anchor; 23. Second anchor hole; 24. Second bolt hole; 3. Bridging plate; 31. Through hole; 4. Waterproof gasket; 5. Bolt; 6. Corner connector; 7. Rail strip plate; 71. Third bolt hole. Detailed Implementation

[0045] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0046] Please see Figure 1-11 It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed in this invention. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0047] Example 1:

[0048] Please see Figure 1-11 An existing tunnel repair structure includes a corrugated plate assembly 1, a foundation 2, a track rail slab 7, and a reinforcement layer, which serve as the main repair structure.

[0049] Please see Figure 1-6The corrugated plate assembly 1 is formed by splicing stainless steel corrugated plates 11 circumferentially along the existing tunnel. Both sides of the stainless steel corrugated plates 11 are provided with reinforcing ribs with inward flanges to increase structural strength, while ensuring that a grouting space is formed between the stainless steel corrugated plates 11 and the inner wall of the existing tunnel after they are fitted and fixed together. The ends of adjacent stainless steel corrugated plates 11 along the circumferential direction of the existing tunnel are fixed together by bridging members. The bridging members include bridging plates 3 with the same waveform as the stainless steel corrugated plates 11, which are lined between the ends of adjacent stainless steel corrugated plates 11. The bridging plates 3 are secured by bolts 5. The end crests of the stainless steel corrugated plate 11 are fixed with bolts 5. The ends of adjacent stainless steel corrugated plates 11 can be fixed with bolts 5. The bridging plate 3 is fixed with the end troughs of the stainless steel corrugated plate 11 and the existing tunnel wall by fasteners. The fasteners can fix the stainless steel corrugated plate 11 to the existing tunnel wall and increase the connection stability between adjacent stainless steel corrugated plates 11. A grouting space is formed between the stainless steel corrugated plate 11 and the existing tunnel wall, providing a prerequisite for grouting micro-expansion high-strength cement mortar to form an integrated structure.

[0050] The bridging component also includes a seepage-proof gasket 4, which is pressed between the bridging plate 3 and the body to be connected. The body to be connected includes a stainless steel corrugated plate 11 and a foot 2. The seepage-proof gasket 4 increases the sealing at the connection points of adjacent stainless steel corrugated plates 11 and the connection points of stainless steel corrugated plates 11 and foot 2, preventing leakage of the repair structure and avoiding overflow of micro-expansion high-strength cement mortar during subsequent grouting.

[0051] Please see Figure 7-9 The upper side of the foot 2 is set as a thermoformed mesh frame structure to increase the structural strength of the foot 2 itself. The upper end of the foot 2 is connected to the lower end of the corrugated plate assembly 1 along the tunnel circumferential direction. The connection structure between the foot 2 and the corrugated plate assembly 1 is the same as the connection structure between the adjacent stainless steel corrugated plate 11, so that the connection form between the foot 2 and the stainless steel corrugated plate 11 and the adjacent stainless steel corrugated plate 11 is the same, reducing the difficulty of connection, and ensuring that the upper end of the foot 2 can also adapt to the waveform of the stainless steel corrugated plate 11, increasing the stability of the connection between the foot 2 and the stainless steel corrugated plate 11.

[0052] Please refer to 10-11. The rail guide plate 7 crosses the existing track and is fixed to the lower end of the foot 2 through the corner connector 6. The two foot 2s are integrated by the rail guide plate 7, so that the corrugated steel assembly 1, foot 2 and rail guide plate 7 form a ring-shaped integral structure, which has good tensile and compressive strength and reliable overall performance.

[0053] The reinforcement layer is formed by micro-expansion high-strength cement mortar injected into the injection space. After the reinforcement layer is formed, it can be fixed to the ring-shaped integral structure formed by the corrugated steel component 1, the anchor 2 and the rail through plate 7, as well as the inner wall of the tunnel, so that the ring-shaped integral structure is fixed to the inner wall of the existing tunnel, thus completing the repair and reinforcement of the existing tunnel.

[0054] Example 2:

[0055] Please see Figure 1-11 An existing tunnel repair structure includes a corrugated plate assembly 1, a foundation 2, a track rail slab 7, and a reinforcement layer, which serve as the main repair structure.

[0056] Please see Figure 1-6 The corrugated plate assembly 1 is formed by splicing stainless steel corrugated plates 11 circumferentially along the existing tunnel. Both sides of the stainless steel corrugated plates 11 are provided with flanges with inner flanges to increase structural strength and facilitate the connection of adjacent stainless steel corrugated plates 11 along the tunnel's longitudinal direction. This also ensures that after the stainless steel corrugated plates 11 are fitted and fixed to the existing tunnel, a grouting space can be formed between them and the inner wall of the existing tunnel. Adjacent stainless steel corrugated plates 11 along the longitudinal direction of the existing tunnel are fixed by the flanges with bolts 5. The ends of adjacent stainless steel corrugated plates 11 along the circumferential direction of the existing tunnel are fixed by bridging components. The bridging components include a liner inside the ends of adjacent stainless steel corrugated plates 11. A bridging plate 3 with the same waveform as the stainless steel corrugated plate 11 is used. The bridging plate 3 is fixed to the end crest of the stainless steel corrugated plate 11 by bolts 5. The ends of adjacent stainless steel corrugated plates 11 can be fixed by bolts 5. The bridging plate 3 is fixed to the end trough of the stainless steel corrugated plate 11 and the existing tunnel inner wall by fasteners. The fasteners can fix the stainless steel corrugated plate 11 to the existing tunnel inner wall and increase the connection stability between adjacent stainless steel corrugated plates 11. A grouting space is formed between the stainless steel corrugated plate 11 and the existing tunnel inner wall, providing the prerequisite for grouting micro-expansion high-strength cement mortar to form an integrated structure.

[0057] The bridging component also includes a seepage-proof gasket 4, which is pressed between the bridging plate 3 and the body to be connected. The body to be connected includes a stainless steel corrugated plate 11 and a foot 2. The seepage-proof gasket 4 increases the sealing at the connection points of adjacent stainless steel corrugated plates 11 and the connection points of stainless steel corrugated plates 11 and foot 2, preventing leakage of the repair structure and avoiding overflow of micro-expansion high-strength cement mortar during subsequent grouting.

[0058] Please see Figure 7-9 The upper side of the foot 2 is set as a thermoformed mesh frame structure to increase the structural strength of the foot 2 itself. The upper end of the foot 2 is connected to the lower end of the corrugated plate assembly 1 along the tunnel circumferential direction. The connection structure between the foot 2 and the corrugated plate assembly 1 is the same as the connection structure between the adjacent stainless steel corrugated plate 11, so that the connection form between the foot 2 and the stainless steel corrugated plate 11 and the adjacent stainless steel corrugated plate 11 is the same, reducing the difficulty of connection, and ensuring that the upper end of the foot 2 can also adapt to the waveform of the stainless steel corrugated plate 11, increasing the stability of the connection between the foot 2 and the stainless steel corrugated plate 11.

[0059] Please refer to 10-11. The rail guide plate 7 crosses the existing track and is fixed to the lower end of the foot 2 through the corner connector 6. The two foot 2s are integrated by the rail guide plate 7, so that the corrugated steel assembly 1, foot 2 and rail guide plate 7 form a ring-shaped integral structure, which has good tensile and compressive strength and reliable overall performance.

[0060] The reinforcement layer is formed by micro-expansion high-strength cement mortar injected into the injection space. After the reinforcement layer is formed, it can be fixed to the ring-shaped integral structure formed by the corrugated steel component 1, the anchor 2 and the rail through plate 7, as well as the inner wall of the tunnel, so that the ring-shaped integral structure is fixed to the inner wall of the existing tunnel, thus completing the repair and reinforcement of the existing tunnel.

[0061] A construction method for repairing existing tunnel structures includes the following steps:

[0062] S1. Preparation: Fix the bolt 5 and the matching waterproof gasket 4 with snap rings inside the first bolt hole 112 at the end of the stainless steel corrugated plate 11 and inside the second bolt hole 24 at the upper end of the foot 2.

[0063] S2. Initial Installation: Place anchors 2 on both sides of the existing track bed foundation. Starting from the top of anchor 2 on either side, place the first stainless steel corrugated plate 11. Confirm that the joint between the stainless steel corrugated plate 11 and anchor 2 is on the same arc. Then, place a bridging plate 3 inside the joint between the stainless steel corrugated plate 11 and anchor 2, and fit the bridging plate 3 through the through hole 31 onto the bolt 5 that fixes the joint between the stainless steel corrugated plate 11 and anchor 2. Tighten the bolt 5 to press the bridging plate 3 onto the anti-seepage gasket 4 and complete the fixing of the joint between the stainless steel corrugated plate 11 and anchor 2. Use the same method to connect adjacent stainless steel corrugated plates 11 along the circumference of the existing tunnel. Finally, fix the last stainless steel corrugated plate 11 to the top of the anchor 2 on the other side.

[0064] S3. Fixed installation: The anchor bolts, which serve as fasteners, are driven into the existing tunnel wall by passing through the remaining unused through holes 31 on the bridging plate 3, the anti-seepage gasket 4, and the first anchor hole 111 on the stainless steel corrugated plate 11 in sequence from the inside to the outside, thereby completing the fixing of the stainless steel corrugated plate 11 to the existing tunnel wall.

[0065] S4. Integrated Connection: A rail-through plate 7 is laid on the existing track, and the end of the rail-through plate 7 is fixed to one leg of the corner joint 6 through the cooperation of the third bolt hole 71 and the bolt 5. Then, the other leg of the corner joint 6 is fixed to the lower end of the anchor 2 through the bolt 5. The anchor bolts, which are fasteners, are driven into the inner wall of the existing tunnel by passing through the remaining unused through hole 31 on the bridge plate 3, the anti-seepage gasket 4 and the second anchor hole 23 on the anchor 2 from the inside to the outside, thus completing the fixation of the anchor 2 to the inner wall of the existing tunnel.

[0066] S5. Grouting: Grouting holes and overflow holes are opened on the installed upper and middle stainless steel corrugated plate 11. Micro-expansion high-strength cement mortar is injected into the grouting space formed between the stainless steel corrugated plate 11 and the existing tunnel inner wall through the grouting holes. The grout flows by itself and the grouting of the whole ring is completed in one go. Wait for the micro-expansion high-strength cement mortar to solidify into a reinforcement layer to complete the reinforcement construction.

[0067] When the inner wall of an existing tunnel needs intermittent repair, the stainless steel corrugated plate 11 used is a corrugated plate with reinforcing ribs and inwardly turned edges, and the construction steps are as described above. When the inner wall of an existing tunnel needs continuous repair, the stainless steel corrugated plate 11 used is a corrugated plate with flanges and inwardly turned edges, and the construction steps, in addition to the above steps, should also include the connection between adjacent stainless steel corrugated plates 11 along the tunnel axis. The flanges of adjacent stainless steel corrugated plates 11 along the tunnel axis are connected by bolts 5, and adjacent stainless steel corrugated plates 11 are staggered to ensure uniform stress distribution in the overall assembly structure and increase the repair and reinforcement effect of the overall assembly structure on the existing tunnel.

[0068] In practice, bolts 5 and matching anti-seepage gaskets 4 are fixed with snap rings inside the first bolt hole 112 at the end of the stainless steel corrugated plate 11 and inside the second bolt hole 24 at the upper end of the anchor 2. Anchors 2 are placed on both sides of the existing track bed foundation. Starting from the upper end of anchor 2 on either side, the first stainless steel corrugated plate 11 is placed, ensuring that the joint between the stainless steel corrugated plate 11 and the anchor 2 is on the same arc. Then, a bridging plate 3 is placed inside the joint between the stainless steel corrugated plate 11 and the anchor 2, ensuring that the anti-seepage gasket 4 and the anchor 2 are properly aligned. The bridging plate 3 is fitted onto the bolts 5 that fix the stainless steel corrugated plate 11 and the anchor 2 at the joint through the through hole 31. Tightening the bolts 5 presses the bridging plate 3 onto the anti-seepage gasket 4 and completes the fixation of the stainless steel corrugated plate 11 and the anchor 2 at the joint. The same method is used to connect adjacent stainless steel corrugated plates 11 along the circumference of the existing tunnel, and finally the last stainless steel corrugated plate 11 is fixed to the upper end of the anchor 2 on the other side. The anchor bolts, which serve as fasteners, are passed through the remaining unused bolts on the bridging plate 3 from the inside to the outside. The through-hole 31, the anti-seepage gasket 4, and the first anchor hole 111 on the stainless steel corrugated plate 11 are driven into the interior of the existing tunnel wall to fix the stainless steel corrugated plate 11 to the existing tunnel wall; the rail strip 7 is laid on the existing track, and the end of the rail strip 7 is fixed to one leg of the corner joint 6 through the cooperation of the third bolt hole 71 and the bolt 5; then the other leg of the corner joint 6 is fixed to the lower end of the anchor 2 through the bolt 5; the anchor bolts, which serve as fasteners, are passed through the remaining unused bolts on the bridge plate 3 from the inside to the outside. The through-hole 31, the anti-seepage gasket 4, and the second anchor hole 23 on the anchor 2 are driven into the interior of the existing tunnel wall to fix the anchor 2 to the existing tunnel wall. Grouting holes and overflow holes are opened on the installed upper stainless steel corrugated plate 11, and micro-expansion high-strength cement mortar is injected into the grouting space formed between the stainless steel corrugated plate 11 and the existing tunnel wall through the grouting holes. The grouting of the whole ring is completed in one go through the self-flow of the grout. Wait for the micro-expansion high-strength cement mortar to solidify into a reinforcement layer to complete the reinforcement construction.

[0069] In summary, the existing tunnel repair structure and construction method of the present invention have the following beneficial effects: The assembled corrugated steel assembly 1 is connected to the track bed as a single ring structure via anchors 2 and track strips 7. It is then fixed to the existing tunnel as a whole by fasteners. Micro-expansion high-strength cement mortar is injected into the grouting space formed between this structure and the inner wall of the existing tunnel. After the micro-expansion high-strength cement mortar solidifies, the structure and the existing tunnel structure form a common load-bearing structure, thereby achieving the purpose of repairing and reinforcing the existing tunnel. This common load-bearing structure has high repair and reinforcement efficiency. The corrugated steel assembly 1 is composed of stainless steel corrugated plates 11 connected with bridging components. The stainless steel corrugated plates 11 themselves have a long service life, and each piece... The stainless steel corrugated plate 11 occupies a small area, is easy to transport, and has low cost. Furthermore, it can be quickly connected after being transported to the tunnel repair location, resulting in high construction efficiency. The stainless steel corrugated plate 11 assembly, using flanged or reinforced inner-flanged flanges, is suitable for continuous or intermittent repair of existing tunnels. By fully utilizing the characteristics of the corrugated plate, it creates a grouting space between itself and the existing tunnel wall, while distinguishing between bolt holes and anchor holes. The anchor holes, combined with fasteners, achieve a dual effect of secure connection between adjacent corrugated plates and fixation between the corrugated plate and the existing tunnel wall. This increases the connection strength between adjacent corrugated plates, enhances the stability of the overall structure, and reduces the number of anchor bolts required. Its widespread application has significant economic and social benefits. Therefore, this invention effectively overcomes the various shortcomings of existing technologies and possesses high industrial applicability.

[0070] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A construction method for repairing existing tunnel structures, characterized in that: The tunnel repair structure includes a corrugated plate assembly (1), a foundation (2), a track rail strip (7), and a reinforcement layer; The corrugated plate assembly (1) is formed by splicing stainless steel corrugated plates (11) along the existing tunnel in a circumferential direction. Both sides of the stainless steel corrugated plates (11) are provided with inward flanges. The ends of adjacent stainless steel corrugated plates (11) are fixed by bridging members. The bridging members include bridging plates (3) lined between the ends of adjacent stainless steel corrugated plates (11). The bridging plates (3) are fixed to the end crests of the stainless steel corrugated plates (11) by bolts (5). The bridging plates (3) are fixed to the end troughs of the stainless steel corrugated plates (11) and the inner wall of the existing tunnel by fasteners, and an injection space is formed between the stainless steel corrugated plates (11) and the inner wall of the existing tunnel. The upper end of the foot (2) is connected to the lower end of the corrugated plate assembly (1) along the tunnel circumferential direction. The connection structure between the foot (2) and the corrugated plate assembly (1) is the same as the connection structure between the adjacent stainless steel corrugated plate (11). The track-passing strip (7) crosses the existing track and is fixed to the lower end of the foot (2); The reinforcement layer is formed by micro-expansion high-strength cement mortar injected into the injection space and then solidified. The bridging component also includes a waterproof gasket (4), which is pressed between the bridging plate (3) and the body to be connected. The body to be connected includes a stainless steel corrugated plate (11) and a foot (2). The stainless steel corrugated plate (11) has a first anchor hole (111) at the end trough position that cooperates with the fastener, and a first bolt hole (112) at the end crest position that cooperates with the bolt (5). The bridging plate (3) is a corrugated plate with the same waveform as the stainless steel corrugated plate (11) and the top waveform of the foot (2). The bridging plate (3) has through holes (31) at both the crest and trough positions. The through holes (31) are waist-shaped holes. The foot (2) is a thermoformed mesh frame structure. The upper trough of the foot (2) is provided with a second anchor hole (23) that cooperates with the fastener. The upper peak of the foot (2) is provided with a second bolt hole (24) that cooperates with the bolt (5). The second anchor hole (23) and the second bolt hole (24) are both strip holes. The lower end of the foot (2) is fixed to one leg of the corner joint (6) by bolts (5), and the other leg of the corner joint (6) overlaps the upper side of the end of the track plate (7) and is fixed by bolts (5); Both ends of the rail strip (7) are provided with a third bolt hole (71) that mates with the bolt (5). The third bolt hole (71) is a waist-shaped hole. The construction method includes the following steps: S1. Preparation: Fix the bolt (5) and the appropriate waterproof gasket (4) to the inside of the first bolt hole (112) at the end of the stainless steel corrugated plate (11) and the inside of the second bolt hole (24) at the upper end of the foot (2) using snap rings. S2. Initial installation: Place anchors (2) on both sides of the existing track foundation. Starting from the top of the anchor (2) on either side, place the first stainless steel corrugated plate (11). Confirm that the joint between the stainless steel corrugated plate (11) and the anchor (2) is on the same arc. Then, place a seepage-proof gasket (4) and a bridging plate (3) inside the joint between the stainless steel corrugated plate (11) and the anchor (2). Make the seepage-proof gasket (4) and the bridging plate (3) fit onto the bolts (5) that fix the joint between the stainless steel corrugated plate (11) and the anchor (2) through the through hole (31). Tighten the bolts (5) to press the bridging plate (3) onto the seepage-proof gasket (4) and complete the fixing of the joint between the stainless steel corrugated plate (11) and the anchor (2). Use the same method to connect adjacent stainless steel corrugated plates (11) along the circumference of the existing tunnel. Finally, fix the last stainless steel corrugated plate (11) to the top of the anchor (2) on the other side. S3. Fixed installation: The anchor bolts, which are fasteners, are driven into the existing tunnel wall by passing through the remaining unused through holes (31) on the bridge plate (3), the anti-seepage gasket (4), and the first anchor hole (111) on the stainless steel corrugated plate (11) from the inside out, so as to complete the fixing of the stainless steel corrugated plate (11) to the existing tunnel wall. S4, Integrated Connection: Lay a rail-through plate (7) on the existing track, and fix one leg of the corner joint (6) at the end of the rail-through plate (7) with the bolt (5) through the third bolt hole (71). Then fix the other leg of the corner joint (6) to the lower end of the anchor (2) through the bolt (5). Drive the anchor bolts, which are fasteners, through the remaining unused through holes (31) on the bridge plate (3), the anti-seepage gasket (4) and the second anchor hole (23) on the anchor (2) from the inside to the outside into the interior of the existing tunnel wall to complete the fixing of the anchor (2) to the existing tunnel wall. S5. Grouting: Grouting holes and overflow holes are opened on the stainless steel corrugated plate (11) installed on the upper side. Micro-expansion high-strength cement mortar is injected into the grouting space formed between the stainless steel corrugated plate (11) and the existing tunnel inner wall through the grouting holes. The grouting of the whole ring is completed in one go by the grout flowing by itself. Wait for the micro-expansion high-strength cement mortar to solidify into a reinforcement layer to complete the reinforcement construction.

2. The construction method for repairing an existing tunnel structure according to claim 1, characterized in that: The inner flange includes two types: flange inner flange and reinforcing rib inner flange. The flange inner flange has evenly distributed axial connection holes at its center along the plate direction of the stainless steel corrugated plate (11).

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