Segmented full-circle lining apparatus and method for long and large tunnels

Abstract

This application discloses a segmented full-circle lining equipment and method for long tunnels. It aims to solve the technical problem in existing technologies where interference between TBM excavation and full-circle lining of tunnels prevents simultaneous construction, resulting in excessively long construction periods and high costs. In this disclosure, the invert arch lining and the side arch lining are poured in stages, with the cleaning platform, rebar platform, side arch lining trolley, and concrete repair platform all equipped with gantry frames for transport tracks. Through the reasonable division of each pair of full-circle lining processes, each process is independent yet coordinated, thereby reducing interference between processes and between full-circle lining and TBM excavation, ensuring timely full-circle lining support of the tunnel, and guaranteeing construction safety within the tunnel.

Description

Technical Field

[0001] This invention application relates to the field of TBM construction technology, specifically to a segmented full-circle lining equipment and method for long tunnels. Background Technology

[0002] The full-face hard rock tunnel boring machine, or TBM for short, is a large-scale tunnel boring machine that integrates mechanical, electronic, hydraulic, and laser control technologies. It can simultaneously carry out tunneling, support, and muck removal operations in parallel and continuously. It has the advantages of fast tunneling speed, environmental friendliness, and high comprehensive benefits. It can realize the construction of long tunnels buried in complex geographical terrain that are difficult to achieve with traditional drill and blast methods.

[0003] Before tunneling, the lateral support shoes at the rear of the cutterhead of the TBM are raised and secured to the tunnel wall to transfer the propulsion reaction force to the tunnel wall. After the support shoes are positioned, the thrust cylinders rotate the cutterhead to begin tunneling. During tunneling, each cutterhead generates propulsion force, causing the surrounding rock at the tunnel face to fracture and form fragments, which are then transported to the outside of the tunnel by a continuous belt conveyor system.

[0004] During TBM construction, tunnels require different levels and types of support. For example, when passing through weak and fractured rock masses with short self-stabilization times, karst areas, fault fracture zones, and areas with large-area water seepage or inrush, advance support is required. After excavation, anchor bolts are installed and steel arch frames are constructed. If necessary, steel mesh and / or shotcrete support are added to prevent collapses and other safety accidents and ensure the safety of construction.

[0005] In addition, long tunnel TBM construction often faces problems such as long construction period, many types of adverse geological conditions, active groundwater environment, and large deformation of soft rock in active faults. In particular, large deformation of soft rock in active faults can easily lead to deformation of the TBM steel arch support, and the tunnel has a great risk of "closing down".

[0006] The inventors are aware of a full-circle tunnel lining system (CN104763443A), which includes a traction system, an internal formwork, a hydraulic system, a top formwork, a bottom formwork, and side formwork. It employs an integrated molding device to achieve the overall construction of the inner wall of a full-circle tunnel. However, in the process of implementing the technical solution in the embodiments of this application, the inventors have discovered that the above-mentioned technology has at least the following technical problems:

[0007] The ventilation ducts, continuous conveyor belts, material transportation, and full-circle lining system required for the construction of long tunnels by TBMs interfere with each other and the construction procedures. Only tunnel excavation or full-circle lining can be carried out at the same time, and the two cannot be carried out simultaneously, resulting in excessively long construction period and increased construction costs.

[0008] The information disclosed in this background section is intended only to enhance the understanding of the background technology of this disclosure and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0009] In view of at least one of the above-mentioned technical problems, this disclosure provides a segmented full-circle lining equipment and method for long tunnels. It aims to solve the technical problem in the prior art where interference between TBM excavation and full-circle tunnel lining occurs, preventing simultaneous construction and resulting in excessively long construction periods and high construction costs.

[0010] According to one aspect of this disclosure, a segmented full-circle lining device for long tunnels is provided, comprising a slag removal platform, an invert lining trolley, a steel reinforcement platform, an invert lining trolley, and a concrete repair platform, which are sequentially arranged from the TBM to the tunnel entrance within the tunnel to be lining. The slag removal platform, steel reinforcement platform, invert lining trolley, and concrete repair platform each include a central gantry for laying transport tracks. The transport tracks include double-track rails corresponding to those laid in the slag removal platform and / or the invert lining trolley, a four-track rail located on the beam of the invert lining trolley, and symmetrical turnouts corresponding to those connecting the double-track rails and the four-track rails and located at corresponding positions at the front end of the invert lining trolley, the front end of the steel reinforcement platform, and the rear end of the concrete repair platform.

[0011] In some embodiments of this disclosure, the slag removal platform includes inclined slag conveyor belts that are staggered along corresponding adjacent sides of the platform and used to lift the slag at the bottom of the tunnel to the continuous conveyor belt at the top of the tunnel.

[0012] In some embodiments of this disclosure, the slag cleaning platform is provided with an electric hoist on the side of the platform through which the transport track passes for lifting the inclined slag conveyor belt.

[0013] In some embodiments of this disclosure, the invert arch lining trolley includes a main beam trestle, inclined rails located at the front and rear ends of the main beam trestle, retractable support legs corresponding to both sides of the main beam and stepping support legs that can move along the main beam, stepping cylinders corresponding to the main beam and the stepping support legs, and a trough-shaped stepping trolley that can slide along the main beam and has telescopic side supports on both sides.

[0014] In some embodiments of this disclosure, the steel reinforcement platform, the side arch lining trolley, and the concrete repair platform each include ventilation duct installation holes for passing through ventilation ducts; the steel reinforcement platform and the concrete repair platform also each include several construction platforms symmetrically arranged on both sides of the frame, and cable hooks are provided below the construction platforms corresponding to the tunnel cable height of the two platforms.

[0015] In some embodiments of this disclosure, a cable rack for placing tunnel cables is provided on one side of the side arch lining trolley; and anti-buoyancy support screws are correspondingly provided between the lining template of the side arch lining trolley and its frame.

[0016] According to another aspect of this disclosure, a method for segmented full-circle lining of long tunnels based on the above-mentioned lining equipment is provided, comprising the following steps:

[0017] (1) Cleaning the bottom of the tunnel: Start the inclined conveyor belt on the side of the cleaning platform from bottom to top, and dump the residual material at the bottom of the tunnel after the TBM excavation to the inclined conveyor belt by manpower or excavator.

[0018] (2) Invert lining: Four-rail tracks are laid on the main beam of the invert lining trolley, and the tracks are connected to the double-rail tracks at the front end of the invert lining trolley by symmetrical turnouts. The invert lining trolley is used to carry out dredging, steel bar binding and invert lining pouring at the bottom of the tunnel. The steel bar binding is carried out by pre-reserving steel bars on both sides of the invert to be constructed.

[0019] (3) Lay side rails on the constructed inverted arch that match the walking assembly of the steel reinforcement platform, the side arch lining trolley and the concrete repair platform.

[0020] (4) The steel reinforcement platform moves on the side rail, and the construction personnel dismantle the ventilation duct, cable and continuous belt at the tunnel wall, and tie the side arch reinforcement on the working platform on both sides of the steel reinforcement platform, and overlap with the reserved reinforcement on both sides of the invert arch to form a ring.

[0021] (5) The side arch lining trolley travels behind the steel reinforcement platform and the ventilation duct, cable and continuous belt disassembled by the steel reinforcement platform pass through the ventilation duct holes of the side arch lining platform, the cable rollers on one side of the side arch lining trolley at the corresponding height, and the continuous belt frame on the other side of the side arch lining trolley.

[0022] (6) After the side arch lining trolley is driven to the lining position, the adjustment cylinders on both sides above the central gantry are adjusted to drive the side arch template to extend, and the side arch template is positioned so that the central axis of the side arch template coincides with the central axis of the tunnel, and waterstops are installed at the edge of the template.

[0023] (7) Concrete is pumped to each window of the side arch lining formwork by a concrete delivery pump, and the construction personnel insert vibrators into each window of the side arch lining formwork at the construction platforms on both sides of the side arch lining trolley to vibrate.

[0024] (8) After the concrete reaches the design strength, the adjusting cylinder and anti-buoyancy support screw of the side arch lining platform are recycled, and the side arch lining formwork is demolded.

[0025] (9) The lining defects after the side arch lining are repaired by using a concrete repair platform that moves behind the side arch lining trolley; and the construction personnel reinstall the ventilation duct, cable and continuous belt on the construction platform on both sides of the concrete repair platform.

[0026] In some embodiments of this disclosure, in step (1), when the TBM railcar passes the slag removal platform, the electric hoist above the central gantry is activated to lift the inclined conveyor belt that interferes with the TBM railcar. After the TBM railcar passes, the corresponding inclined conveyor belt is lowered back to its original position.

[0027] In some embodiments of this disclosure, in step (2), when the invert lining trolley moves, the telescopic outriggers on both sides of the trolley are retracted, and sleepers are laid under each stepping outrigger and stepping trolley on both sides. The stepping motor of the stepping outrigger is started to drive the invert lining trolley to move forward. After the invert lining trolley moves into place, the telescopic outriggers are extended. After each stepping outrigger and stepping trolley is disengaged from the corresponding sleeper, the sleeper is removed.

[0028] In some embodiments of this disclosure, in step (6), after the side arch template is positioned, an anti-buoyancy support screw is set between the side arch lining trolley frame and the side arch template to assist in positioning.

[0029] One or more technical solutions provided in the embodiments of this application have at least one of the following technical effects or advantages:

[0030] 1. The invert arch lining and the side arch lining are connected and poured in stages. The cleaning platform, the steel reinforcement platform, the side arch lining trolley, and the concrete repair platform are all equipped with gantry frames for transport tracks. By reasonably dividing each pair of full-circle lining processes, each process is independent and coordinated with each other, thereby reducing interference between processes and between full-circle lining and TBM excavation, ensuring timely full-circle lining support of the tunnel, and ensuring construction safety in the tunnel.

[0031] 2. The steel reinforcement platform, the side arch lining trolley, and the concrete repair platform are used for steel reinforcement binding, dismantling of auxiliary facilities at the tunnel wall, side arch lining, post-lining repair, and reinstallation of auxiliary facilities at the tunnel wall, respectively. This avoids interference from ventilation ducts, continuous belts, and cables with the full circular lining, thereby helping to improve construction efficiency.

[0032] 3. A transport track including double-track, four-track and symmetrical turnouts is set up so that the TBM transport vehicle can still pass through each platform / cart while it is working. This ensures the synchronous construction between TBM excavation and tunnel full-circle lining, thereby achieving timely lining after tunnel excavation. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the track changing structure in one embodiment of this application.

[0034] Figure 2 This is a schematic diagram of the structure of the arch lining trolley in one embodiment of this application.

[0035] Figure 3 This is a schematic diagram of the side arch construction in one embodiment of this application.

[0036] Figure 4 This is a schematic diagram of the steel bar support structure in one embodiment of this application.

[0037] Figure 5 This is a schematic diagram of the structure of the side arch lining trolley in one embodiment of this application.

[0038] Figure 6 This is a schematic diagram of the structure of a concrete repair platform in one embodiment of this application.

[0039] In the above figures, 11 is a four-rail track, 12 is a symmetrical turnout, 13 is a double-rail track, 21 is a main beam trestle, 22 is a ramp rail, 23 is a telescopic outrigger, 24 is a stepping outrigger, 25 is a stepping cylinder, 26 is a stepping trolley, 30 is a ventilation duct, 31 is a steel reinforcement platform, 32 is a side arch lining trolley, 33 is a concrete repair platform, 41 is a side arch lining trolley working platform, 42 is a cable rack, 43 is a belt conveyor, 44 is a lining template, 45 is a template cylinder, 46 is an anti-buoyancy support screw, and 51 is a crossbeam of the concrete repair platform. Detailed Implementation

[0040] In the description of this application, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," "outer," "vertical," "horizontal," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "connection" and "linkage" in this application, unless otherwise specified, include both direct and indirect connections (linkages).

[0041] To better understand the technical solution of this application, the above technical solution will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0042] This example discloses a segmented full-circle lining equipment for long tunnels, which is used to sequentially and mutually cooperate with a slag removal platform, an invert arch lining trolley, a steel reinforcement platform, a side arch lining trolley, a concrete repair platform, and corresponding transport tracks in the tunnel to be lining after TBM excavation, from the tail of the TBM to the tunnel entrance.

[0043] After TBM excavation, a certain amount of excavated rock remains at the bottom of the tunnel. When the excavated rock is transported to the outside of the tunnel via the TBM continuous belt conveyor system, equipment vibration or uneven rock accumulation can cause the conveyor belt to deviate, resulting in some rock falling off the conveyor. This residual rock at the tunnel bottom will adversely affect the subsequent construction of the invert. Therefore, it is necessary to clean the residual rock at the bottom of the tunnel before invert construction. In this example, a cleaning platform is set up to complete the cleaning operation at the bottom of the tunnel. To facilitate the convenient transportation of the cleaned rock to the outside of the tunnel, the cleaning platform has a certain height to enable lifting operations. In this example, the height of the cleaning platform is adapted to the deployment height of the TBM continuous belt conveyor, so that the excavated rock can be transported to the outside of the tunnel using the continuous belt conveyor. To facilitate the lifting of the residue, inclined conveyor belts are installed on adjacent sides of the slag-cleaning platform to lift the slag from the bottom of the platform to the conveyor belt at the top. These inclined conveyor belts are staggered. Specifically, in this embodiment, three levels of inclined conveyor belts are installed on three adjacent sides of the slag-cleaning platform. The highest level of the third-level inclined conveyor belt ends directly above the continuous conveyor belt of the TBM, while the lowest level of the first-level inclined conveyor belt ends above the second-level inclined conveyor belt. The cleaning platform is positioned above a three-stage inclined muck conveyor belt. Through the sequential lifting of the three-stage inclined muck conveyor belts, the residue at the bottom of the tunnel can be transported to the outside of the tunnel via the TBM continuous conveyor belt. The bottom of the cleaning platform is equipped with a traveling assembly that can move along the laid track. This ensures that the center of the platform coincides with the center of the tunnel, so that the tail of the inclined muck conveyor belt is always directly above the TBM continuous conveyor belt. On the other hand, it improves the flexibility of the cleaning platform, allowing it to be moved to different positions for cleaning operations, which helps to improve the efficiency of the operation.

[0044] In this example, during TBM tunneling, rail transport vehicles shuttle between the TBM and the external working area to transport materials. To avoid interference between the slag removal platform and the rail transport workshop, the slag removal platform includes a portal frame structure with a central gantry at its center. This allows the rail transport vehicles to pass through the central gantry. Considering the limited width of the central gantry and the fact that transport tracks are generally divided into uphill and downhill lines, symmetrical turnouts are used in this embodiment to connect and switch between different tracks. For details, see [link to details]. Figure 1 In this embodiment, the rail transport vehicle uses a four-rail track 11, with separate uphill and downhill lines. When passing the slag removal platform, the width of the central gantry of the slag removal platform is limited, which cannot meet the requirement of laying four rails within the central gantry area. Therefore, a symmetrical turnout 12 is set up to change the transport track line. One end of the symmetrical turnout 12 is a double rail, and the other end is a single rail. It is equipped with a switch. The connection relationship between the single rail and any of the double rails is adjusted by the switch, thereby realizing the change from double rail to single rail. The vehicle passes through the slag removal platform via the double rail 13 that passes through the central gantry of the slag removal platform, thereby solving the interference relationship between the platform and the rail transport and realizing the slag removal operation while the rail transport operation is being carried out.

[0045] In this embodiment, since the three-stage inclined conveyor belts at the slag removal platform are located on the side adjacent to the platform, the lowest-level inclined conveyor belt will interfere with the portal of the central gantry, obstructing the passage of the rail transport vehicle. Therefore, in this embodiment, an electric hoist is installed at the top of the slag removal platform. The hook of the electric hoist is connected to the first-stage inclined conveyor belt. When a rail transport vehicle passes by, the electric hoist is activated to lift the first-stage conveyor belt, thus avoiding interference with the transport vehicle.

[0046] In some other embodiments, in order to avoid laying additional running tracks for the slag cleaning platform, four tracks are laid in front of and behind the slag cleaning platform, and a four-track three-line transportation system is adopted. The slag cleaning platform runs on the two outermost tracks of the four-track three-line system, while the other two tracks serve as the running lines for rail transport vehicles, which can directly pass through the central gantry of the slag cleaning platform.

[0047] After the debris at the bottom of the tunnel is cleared using a cleaning platform, the full-circle lining of the tunnel can begin. However, full-circle lining prevents the rail transport vehicle from transporting excavated materials, and causes the TBM excavation cables and continuous conveyor belts installed on the tunnel walls to malfunction, leading to a halt in TBM excavation and impacting the construction schedule. Therefore, in this embodiment, the full-circle lining process is rationally divided into invert arch construction and side arch construction, with steel reinforcement overlapping between the two to form a closed loop. This ensures that TBM excavation can proceed simultaneously with the full-circle tunnel lining.

[0048] After the slag removal operation, the invert arch is constructed first. Since the invert arch is located at the bottom of the tunnel and interferes with the rail transport line, in order to ensure that the rail transport vehicle can carry out TBM excavation material transportation operations normally while the invert arch is being constructed, in this embodiment, an invert arch lining trolley is used for invert arch pouring. See details below. Figure 2The invert lining trolley includes a main beam trestle 21, inclined rails 22, telescopic outriggers 23, stepping outriggers 24, stepping cylinders 25, and a trough-shaped stepping trolley 26 with telescopic side supports. The main beam trestle 21 is the main structure of the invert lining trolley, with several telescopic outriggers 23 on both sides. The telescopic outriggers 23 allow the invert lining trolley to be raised above the tunnel floor by a certain height, thus creating a working space for invert lining under the main beam trestle. To avoid interference between the invert lining trolley and the rail transport workshop, inclined rails 22 are provided at both the front and rear ends of the main beam trestle 21. The main beam trestle 21 has four rails, which are double rails. As described above, the front and rear ends of the main beam trestle 21 are connected to the four rails on the main beam trestle using symmetrical turnouts, thereby meeting the passage requirements of the rail transport vehicle.

[0049] Considering that the invert lining trolley needs to move forward continuously to carry out the lining work of the next section of the invert, in this example, stepping legs 24 are respectively set on both sides of the front and rear sections of the invert lining trolley. The stepping legs are equipped with track wheels clamped at both ends of the beam wall on one side of the main beam, so that the stepping legs 24 can move along the main beam of the trolley. In addition, a stepping cylinder 25 is also provided between the main beam and the stepping legs 24. Thus, when the invert lining trolley needs to move, the support of the invert lining trolley is switched from the telescopic legs 23 to the stepping legs 24. Then, through the extension and retraction of the stepping cylinder 25, the main beam is driven to slide forward between the track wheels of the stepping legs 24, thereby realizing the movement of the invert lining trolley. In addition, in this embodiment, in order to facilitate the forward movement and stability of the middle part of the invert lining trolley, a stepping trolley 26 is provided in the middle part of the invert lining trolley. The stepping trolley has a trough-shaped structure. The main beam of the invert lining trolley is placed in the trough and can slide along the trough. The two sides of the trough wall are provided with retractable side supports, so that the stability of the trolley movement is ensured by the side supports when the trolley moves forward.

[0050] After the invert arch is constructed, the side arch is constructed. Because TBM tunneling cables, continuous conveyor belts, and ventilation ducts are installed on both sides and the top of the tunnel, these auxiliary facilities at the tunnel wall will interfere with the side arch lining during construction. Therefore, in this embodiment, see... Figure 3 The lining operation of the side arch is carried out by setting up steel reinforcement platform 31, side arch lining trolley 32, and concrete repair platform 33 in sequence.

[0051] The steel reinforcement platform is mainly used for tying the side arch reinforcement and dismantling the auxiliary structures at the tunnel wall. For its specific structure, please refer to [link to relevant documentation]. Figure 4The bottom of the rebar platform 31 is equipped with a traveling assembly, including a central gantry structure, to prevent interference between the rebar platform and the rail transport workshop. Rails are then laid within the central gantry area to meet the passage requirements of the rail transport vehicle. However, due to the limited width of the central gantry of the rebar platform, four-rail systems cannot be laid. (See [link to relevant documentation]). Figure 1 The four-track system is converted to a double-track system via symmetrical turnouts to facilitate movement through the central gantry of the rebar platform. In other embodiments, the rebar gantry travels on the outermost two tracks of the four-track system, while the remaining two tracks pass through the central gantry of the rebar platform for transport by rail transport vehicles. Furthermore, to facilitate rebar tying, the rebar platform includes a three-tiered working platform, see [link to relevant documentation]. Figure 4 Construction workers tied the reinforcing steel bars for the tunnel arch at work platforms at different heights and dismantled the continuous conveyor belt and cables from the tunnel wall. Cable hooks were installed on one side of the cables on the corresponding section of the tunnel wall at the rebar platform for temporary placement after dismantling. To facilitate the dismantling and placement of the ventilation duct at the tunnel ceiling, and considering the duct's flexibility, a ventilation duct installation hole was provided above the central gantry of the rebar platform. The size and structure of this hole matched the ventilation duct to provide temporary support for the dismantled duct.

[0052] After dismantling the auxiliary facilities at the tunnel wall and tying the corresponding reinforcing bars using a steel reinforcement platform, the lining work for the tunnel side arch can be carried out. In this embodiment, see... Figure 3 The lining work of the side arch section is carried out by a side arch lining trolley that moves behind the steel reinforcement platform. See details below. Figure 5The side arch lining trolley is equipped with two working platforms 41 for placing grouting equipment and providing support for construction personnel. It also includes a central gantry structure for mounting double rails to avoid affecting TBM excavation during side arch lining. In addition, ventilation holes are provided above the central gantry to temporarily support the ventilation ducts after dismantling the steel frame, preventing the ventilation ducts from interfering with the lining operation. Cable racks 42 and belt racks 43 are provided on both sides of the side arch lining trolley to provide temporary support for the dismantled cables and continuous belt conveyors, respectively. This completely avoids the impact of tunnel ancillary facilities on tunnel lining. Furthermore, due to the corresponding support on both sides of the trolley, the normal operation of cables, continuous belt conveyors, and ventilation ducts will not be interrupted when the side arch lining trolley moves forward as the work progresses. In addition, the lining trolley for the side arch also includes a lining template 44, which is used for pouring the side arch. It is connected to the trolley via several template cylinders 45. The extension and retraction of the template cylinders 45 ensures the lining template moves into place. In this embodiment, considering that the concrete grout, due to its weight and pressure, may cause displacement and floating after being poured into the template, several anti-buoyancy support screws 46 are also provided between the lining template 44 and the trolley beams and columns. The self-locking action of these screws prevents the lining template 44 from floating under the pressure of the concrete grout.

[0053] After the side arch lining trolley is used for pouring the side arch lining, it is necessary to restore the auxiliary facilities inside the tunnel to their original positions on the tunnel wall, and the lining quality must be inspected to ensure the safety and reliability of the construction. For this purpose, see [link to relevant documentation]. Figure 3 In this embodiment, a concrete repair platform 33 operates behind the side arch lining trolley 32, as detailed below. Figure 6 The platform also includes a central gantry for double-track operation. Above the central gantry are ventilation duct installation holes. Since this concrete repair platform needs to re-hang the ventilation duct at the tunnel ceiling, for ease of operation, the ventilation duct installation holes are raised from the front to the rear of the concrete repair platform via crossbeams 51 at different heights. This allows the ventilation duct 30 to gradually approach the tunnel ceiling under the action of the sequentially raised crossbeams 51, thereby reducing the workload of construction personnel, lowering the difficulty of ventilation duct installation, and avoiding the need for lifting equipment to enter the site and interfere with the synchronous excavation of the TBM. Furthermore, the concrete repair platform has symmetrically arranged operation platforms of different heights on both sides, used for re-hanging cables and belt conveyors at the tunnel wall and for inspecting and repairing the side arches after lining, preventing defects such as honeycomb, pitting, and holes.

[0054] This example also discloses a method for segmented full-circle lining of long tunnels using the aforementioned lining equipment, which specifically includes the following steps:

[0055] (1) Tunnel bottom cleaning: Start the inclined conveyor belt on the side of the cleaning platform from bottom to top, and dump the tunnel bottom residue after TBM excavation to the inclined conveyor belt by manpower or excavator.

[0056] Because a certain amount of residue will remain at the bottom of the tunnel after the TBM excavation, and a certain amount of slag will fall to the bottom of the tunnel due to vibration or slag stacking problems during transportation by the continuous belt conveyor hanging on the tunnel wall, and the residue at the bottom of the tunnel will affect the construction of the invert arch, the slag removal operation at the bottom of the tunnel must be carried out before the construction of the invert arch.

[0057] The muck-cleaning platform enters the site after the TBM has excavated and formed the tunnel. Once the platform has moved along the track to the area to be cleaned, it is brought to a complete stop, and a vehicle stop is installed to prevent movement during operation. Then, the inclined muck-carrying conveyor belts on adjacent sides of the platform are activated sequentially from bottom to top to ensure reliable connection between each belt level and prevent muck accumulation at any level, thus avoiding muck falling. It is also ensured that the end of the highest belt is directly above the TBM's continuous conveyor belt, so that the muck at the tunnel bottom can be transported by the TBM to the spoil disposal site outside the tunnel.

[0058] Because the central gantry of the slag removal platform is equipped with corresponding rails, and the inclined slag conveyor belt on the side of the platform interferes with the passage of vehicles along the rails, when the rail transport vehicle needs to pass through the slag removal platform, the electric hoist on the top of the slag removal platform is activated, thereby driving the corresponding inclined slag conveyor belt to rise vertically. Once the inclined slag conveyor belt no longer interferes with the rail transport vehicle, the operation of the electric hoist is stopped. After the rail transport vehicle passes through the slag removal platform, the inclined slag conveyor belt below the electric hoist is activated again to its original position, and the slag is then shoveled and transported by manpower or mechanical equipment to the lowest inclined slag conveyor belt for slag removal.

[0059] (2) Invert lining: Four-rail three-line track is laid on the main beam of the invert lining trolley, and the track is connected to the double track at the front end of the invert lining trolley by symmetrical turnouts. The invert lining trolley is used to carry out dredging, steel bar binding and invert lining pouring at the bottom of the tunnel. The steel bar binding operation is carried out by reserving steel bars on both sides of the invert to be constructed.

[0060] After a certain length of slag removal from the tunnel floor, the invert lining trolley can be installed behind the slag removal platform. Once the invert lining trolley is in place, a four-rail, three-line system is laid above its main beam, and symmetrical turnouts connect it to the double rails of the trolley's inclined rail section. This ensures unobstructed transport, allowing the transport railcar to run on the main beam of the invert lining trolley without interfering with the construction of the invert below. Furthermore, the area below the main beam of the invert lining trolley is divided into several work zones for sludge removal, rebar tying, and invert lining pouring, respectively.

[0061] Because the cleaning platform can only remove relatively large pieces of slag, smaller pieces of slag or mud will remain at the bottom of the tunnel. This mud needs to be removed before the invert lining is installed to avoid affecting its quality. Therefore, dredging is performed before invert construction. In this example, dredging is done by washing with clean water, and then pumping out the slag to ensure the relative cleanliness of the tunnel floor walls, facilitating the subsequent invert pouring.

[0062] In this example, the rebar tying work station is divided into three sections, each 12 meters long, equipped with four CO2 shielded welding machines and four impact drills. First, the survey and layout are carried out, and holes are drilled according to the layout points. Positioning bars are placed in the holes. Then, the lower longitudinal bars and circumferential bars are welded at the positions of the positioning bars. After the lower layer of bars is tied, the upper layer of bars is tied in the same way. Finally, the rail abutment bars are tied. During the rebar tying, rebars are reserved on both sides of the invert arch to be poured, so as to facilitate the lap splicing of the side arch bars and tie them into a ring.

[0063] After the invert arch reinforcement is tied, the invert arch is poured. An invert arch formwork system is used, including a central drainage ditch formwork, longitudinal beams, invert arch curved formwork, front and rear end supports, and lifting and lateral adjustment mechanisms. First, the position of each formwork is adjusted to the design position using the lifting and lateral adjustment mechanisms. Then, air cushions are used to support both ends of the formwork to complete positioning and sealing. Concrete grout is poured into the formwork through the corresponding working windows, and vibrators are inserted to compact the grout. After the concrete reaches the design strength, demolding is performed. First, the air in the air cushions at both ends of the formwork is released, then the air cushions are removed, and the lifting and lateral adjustment mechanisms are used to raise the formwork, completing the demolding.

[0064] After completing the lining of the current section of the invert arch, the invert arch lining trolley needs to move forward to proceed with the lining of the next section. Specifically, during the forward movement of the invert arch, sleepers of appropriate height are first placed under each stepping leg and stepping trolley. The telescopic legs on both sides of the trolley's main beam are then retracted, bringing the stepping legs and stepping trolley into contact with the sleepers, where the stepping legs bear the load. Simultaneously, the side supports on both sides of the stepping trolley are extended, and then the stepping cylinders connecting the stepping legs and the main beam are driven, causing the main beam to move forward relative to the stepping legs and stepping trolley. After moving the designed distance, the side supports of the stepping trolley are retracted, the stepping cylinders are retracted, and the telescopic legs are extended, disengaging the stepping cylinders from the sleepers. The trolley is then supported by the telescopic legs, and this process is repeated to achieve the forward movement of the invert arch lining trolley. In some other embodiments, sleepers are not placed under the stepping trolley during the forward movement of the trolley.

[0065] (3) Lay side rails on the constructed inverted arch that match the walking assembly of the steel reinforcement platform, the side arch lining trolley and the concrete repair platform.

[0066] After the invert arch is completed, considering the subsequent entry and forward movement of the side arch lining equipment, a track is laid on the invert arch. In this embodiment, a four-rail three-line system track is laid at the invert arch. The track is connected to the inclined rail at the rear end of the invert arch lining trolley through symmetrical turnouts. The side arch lining equipment travels on the two outermost tracks of the four-rail three-line system track. By arranging symmetrical turnouts at corresponding positions, the transport vehicle passes through the central gantry of the side arch lining equipment.

[0067] (4) The steel reinforcement platform moves on the side rail, and the construction personnel dismantle the ventilation duct, cable and continuous belt at the tunnel wall, and tie the side arch reinforcement on the working platform on both sides of the steel reinforcement platform, and overlap with the reserved reinforcement on both sides of the invert arch to form a ring.

[0068] After the invert arch and corresponding track laying are completed, the steel reinforcement platform is brought in first. Construction workers then tie the side arch reinforcement at construction platforms at different heights on the steel reinforcement platform, ensuring that the side arch reinforcement is integrated with the reserved reinforcement on both sides of the invert arch to guarantee the structural stability of the side arch. In addition, construction workers dismantle cables, ventilation ducts, and continuous conveyor belts at construction platforms at corresponding heights, and accordingly hang the cables on cable hooks below the construction platform and pass the ventilation ducts through the ventilation duct installation holes in the center of the platform.

[0069] (5) The side arch lining trolley travels behind the steel reinforcement platform and passes through the ventilation duct, cable and continuous belt that were disassembled through the steel reinforcement platform through the ventilation duct holes of the side arch lining platform, the cable rollers on one side of the side arch lining trolley at the corresponding height, and the continuous belt frame on the other side of the side arch lining trolley.

[0070] After the steel reinforcement platform is dismantled for tunnel ancillary installations, including ventilation ducts, cables, and continuous conveyor belts, the side arch lining trolley enters the site to carry out side arch lining operations. Since the steel reinforcement platform alone cannot provide reliable temporary support for the dismantled ancillary facilities, the cables are placed on the cable rack rollers on one side of the side arch lining trolley, the continuous conveyor belt is correspondingly installed on the continuous conveyor belt rack on the other side of the side arch lining trolley, and the ventilation ducts are placed in the ventilation duct installation holes on the top of the trolley to achieve reliable temporary support.

[0071] (6) After the side arch lining trolley is driven to the lining position, the adjustment cylinders on both sides above the central gantry are adjusted to drive the side arch template to extend, and the side arch template is positioned so that the central axis of the side arch template coincides with the central axis of the tunnel, and waterstops are installed at the edge of the template.

[0072] After the side arch lining trolley moves to the lining position, the formwork cylinder is driven to adjust the position of the lining formwork. During the adjustment process, waterstops are inserted at the edges of the formwork. To ensure the stability of the lining formwork, anti-buoyancy support screws are used to fix the lining formwork while the formwork cylinder is tightening it. The self-locking of the screws prevents the formwork from loosening due to pressure relief from the formwork cylinder. In addition, the central axis of the formwork must be aligned with the central axis of the tunnel based on the positional relationship between the side arch lining trolley and the tunnel's central axis.

[0073] (7) Concrete is pumped to each window of the side arch lining formwork by a concrete delivery pump, and the construction personnel insert vibrators into each window of the side arch lining formwork at the construction platforms on both sides of the side arch lining trolley to vibrate.

[0074] (8) After the concrete reaches the design strength, the adjusting cylinder and anti-buoyancy support screw of the side arch lining platform are recycled, and the side arch lining formwork is demolded.

[0075] (9) The lining defects after the side arch lining are repaired by using a concrete repair platform that moves behind the side arch lining trolley; and the construction personnel reinstall the ventilation duct, cable and continuous belt on the construction platform on both sides of the concrete repair platform.

[0076] After the side arch lining is completed, the lining quality needs to be inspected and defects repaired. Therefore, a concrete repair platform is operated behind the side arch lining trolley. Using the construction platforms on both sides of this platform, defects such as honeycomb, pitting, and voids in the lining can be repaired. It also allows for the reinstallation of cables and continuous conveyor belts at the tunnel wall. Furthermore, by using crossbeams arranged at progressively higher heights at the openings in the ventilation duct on the platform, the ventilation duct can be gradually raised to its final tangent to the tunnel roof. This facilitates the installation of the ventilation duct by construction personnel and avoids the impact of hoisting equipment on the TBM's synchronous excavation.

[0077] Although some preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0078] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of the invention. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A method for segmented full-circle lining of long tunnels, characterized in that, This system is implemented based on a segmented full-circle lining equipment for long tunnels. The segmented full-circle lining equipment for long tunnels includes a slag removal platform, an invert lining trolley, a steel reinforcement platform, an invert lining trolley, and a concrete repair platform, which are sequentially installed in the tunnel to be lining from the TBM to the tunnel entrance. The slag removal platform, steel reinforcement platform, invert lining trolley, and concrete repair platform each include a central gantry for laying transport tracks. The transport tracks include double-track tracks corresponding to the slag removal platform and / or the invert lining trolley, a four-track track located on the beam of the invert lining trolley, and symmetrical turnouts corresponding to the double-track tracks and the four-track tracks and located at the front end of the invert lining trolley, the front end of the steel reinforcement platform, and the rear end of the concrete repair platform. The segmented full-circle lining method for long tunnels includes the following steps: (1) Tunnel bottom cleaning: Start the inclined muck conveyor belt on the side of the cleaning platform from bottom to top, and dump the residual muck at the bottom of the tunnel after TBM excavation by manpower or excavator to the inclined muck conveyor belt. (2) Invert lining: Four-rail tracks are laid on the main beam of the invert lining trolley, and the tracks are connected to the double-rail tracks at the front end of the invert lining trolley by symmetrical turnouts. The invert lining trolley is used to carry out dredging, steel bar binding and invert lining pouring at the bottom of the tunnel. The steel bar binding is carried out by pre-reserving steel bars on both sides of the invert to be constructed. (3) Lay side rails on the constructed inverted arch that match the walking assembly of the steel reinforcement platform, the side arch lining trolley and the concrete repair platform. (4) The steel reinforcement platform moves on the side rail, and the construction personnel dismantle the ventilation duct, cable and continuous belt at the tunnel wall, and tie the side arch reinforcement on the working platform on both sides of the steel reinforcement platform, and overlap with the reserved reinforcement on both sides of the invert arch to form a ring. (5) The side arch lining trolley travels behind the steel reinforcement platform and the ventilation duct, cable and continuous belt disassembled by the steel reinforcement platform pass through the ventilation duct holes of the side arch lining platform, the cable rollers on one side of the side arch lining trolley at the corresponding height, and the continuous belt frame on the other side of the side arch lining trolley. (6) After the side arch lining trolley is driven to the lining position, the adjustment cylinders on both sides above the central gantry are adjusted to drive the side arch template to extend, and the side arch template is positioned so that the central axis of the side arch template coincides with the central axis of the tunnel, and waterstops are installed at the edge of the template. (7) Concrete is pumped to each window of the side arch lining formwork by a concrete delivery pump, and the construction personnel insert vibrators into each window of the side arch lining formwork at the construction platforms on both sides of the side arch lining trolley to vibrate. (8) After the concrete reaches the design strength, the adjusting cylinder and anti-buoyancy support screw of the side arch lining platform are recycled, and the side arch lining formwork is demolded. (9) The lining defects after the side arch lining are repaired by using a concrete repair platform that moves behind the side arch lining trolley; and the construction personnel reinstall the ventilation duct, cable and continuous belt on the construction platform on both sides of the concrete repair platform.

2. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, The slag removal platform includes inclined slag conveyor belts that are staggered along the corresponding adjacent sides of the platform and used to lift the slag at the bottom of the tunnel to the continuous conveyor belt at the top of the tunnel.

3. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, The slag cleaning platform is equipped with an electric hoist on the side of the platform corresponding to the transport track for lifting the inclined slag conveyor belt.

4. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, The arch lining trolley includes a main beam trestle, inclined rails at the front and rear ends of the main beam trestle, retractable support legs on both sides of the main beam and stepping support legs that can move along the main beam, stepping cylinders connected between the main beam and the stepping support legs, and a trough-shaped stepping trolley that can slide along the main beam and has telescopic side supports on both sides.

5. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, The steel reinforcement platform, the side arch lining trolley, and the concrete repair platform each include ventilation duct installation holes for passing through ventilation ducts; the steel reinforcement platform and the concrete repair platform also include several construction platforms symmetrically arranged on both sides of the frame, and cable hooks are provided below the construction platforms corresponding to the height of the tunnel cable on both platforms.

6. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, The side arch lining trolley is provided with a cable rack for placing tunnel cables on one side; and anti-buoyancy support screws are provided between the lining template and the frame of the side arch lining trolley.

7. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, In step (1), when the TBM railcar passes the slag removal platform, the electric hoist above the central gantry is activated to lift the inclined slag conveyor belt that interferes with the TBM railcar. After the TBM railcar passes, the corresponding inclined slag conveyor belt is lowered back to its original position.

8. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, In step (2), when the invert lining trolley moves, the telescopic outriggers on both sides of the trolley are retracted accordingly, and sleepers are laid under each stepping outrigger and stepping trolley on both sides. The stepping motor of the stepping outrigger is started to drive the invert lining trolley to move forward. After the invert lining trolley moves into place, the telescopic outriggers are extended accordingly. After each stepping outrigger and stepping trolley is separated from the corresponding sleeper, the sleeper is removed.

9. The segmented full-circle lining method for long tunnels according to claim 1, characterized in that, In step (6), after the side arch template is positioned, an anti-buoyancy support screw is set between the side arch lining trolley frame and the side arch template to assist in positioning.

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