A fully prefabricated three-layer shield tunnel structure and its construction method

Abstract

This invention discloses a fully prefabricated three-layer shield tunnel structure and its construction method, relating to the technical field of building construction. The tunnel structure includes prefabricated shield tunnel segments, a prefabricated butterfly-shaped lower lane slab, and a prefabricated upper lane slab. The construction method includes: first, using a shield tunneling machine to excavate and assemble the prefabricated shield tunnel segments to form the shield tunnel; second, transporting and unfolding the prefabricated butterfly-shaped lower lane slab inside the tunnel to form the lower lane structure; and then, inserting the prefabricated upper lane slab downwards and fully positioning it to form a stable three-layer tunnel structure. This invention employs a flexible connection method for prefabricated components, achieving 100% prefabrication of the three-layer structure within the shield tunnel. This avoids the use of post-cast joints in traditional construction, solves technical problems such as dust, heat of hydration, and exhaust gas in the tunnel environment of existing solutions, and improves the cleanliness and safety of the construction environment.

Description

Technical Field

[0001] This invention belongs to the technical field of building construction, specifically relating to a fully prefabricated three-layer shield tunnel structure and its construction method. Background Technology

[0002] Currently, the multi-level lane structure inside shield tunnels in China is still mainly constructed using semi-prefabricated methods, which combine prefabricated components with cast-in-place concrete. The lower lane uses "□ / π" shaped prefabricated components to form a construction access road during the construction period, facilitating the transportation of tunnel segments and other related materials and enabling simultaneous construction. The remaining structures are mainly constructed using cast-in-place methods. In order to promote the industrialization of the construction industry, the industry is constantly trying prefabrication schemes and continuously improving the prefabrication rate. However, the schemes are still in the form of "prefabricated components + post-cast joints". Although the prefabrication rate is constantly improving, the presence of post-cast joints means that the environment inside the tunnel is still affected by dust, hydration heat, and exhaust gas. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a fully prefabricated three-layer shield tunnel structure and its construction method. The prefabricated components do not require post-cast joints and are fully flexibly connected, achieving a 100% prefabrication and assembly rate. This solves the technical problems of existing solutions that result in dust, hydration heat, and exhaust gas in the tunnel environment.

[0004] This invention provides a fully prefabricated three-layer shield tunnel structure, employing the following technical solution:

[0005] A fully prefabricated three-layer shield tunnel structure includes prefabricated shield tunnel segments, a prefabricated butterfly-shaped lower lane slab, and a prefabricated upper lane slab. The prefabricated shield tunnel segments are assembled to form a shield tunnel. The prefabricated butterfly-shaped lower lane slab can be unfolded or retracted. When unfolded, the prefabricated butterfly-shaped lower lane slab is located in the lower middle part of the shield tunnel and forms the lower space of the tunnel structure with the bottom of the shield tunnel. The lower space is the equipment layer. The prefabricated upper lane slab is located above the prefabricated butterfly-shaped lower lane slab and forms the middle space of the tunnel structure with the prefabricated butterfly-shaped lower lane slab. The middle space is the lower lane layer. The prefabricated upper lane slab forms an upper space with the shield tunnel. The upper space is the upper lane layer.

[0006] Preferably, the precast butterfly-shaped lower lane slab includes a steel column-shaped swivel bearing, a steel shaft fixing arm, a reinforced concrete swivel arm, a winch-type steel cable opening and closing device, and a limiting steel cable; the two reinforced concrete swivel arms are symmetrically arranged, one end of each of the two reinforced concrete swivel arms is connected to the steel shaft fixing arm, the ends of the two steel shaft fixing arms are connected by the steel column-shaped swivel bearing, and the winch-type steel cable opening and closing device is connected to the end of the two reinforced concrete swivel arms away from the steel shaft fixing arm by the limiting steel cable;

[0007] The opening of the winch-type steel cable opening and closing device can drive the two reinforced concrete rotating arms to extend or retract.

[0008] Preferably, the reinforced concrete rotating arm includes a bottom support arm and a side support arm, which are integrally formed. The outer side of the side support arm is in contact with the inner side of the precast tunnel segment, and the inner side of the bottom support arm is parallel to the tangent at the bottom of the precast tunnel segment after it is unfolded.

[0009] Preferably, the side support arm has a stepped groove at the end away from the bottom support arm, and the prefabricated upper lane slab is inserted between the stepped grooves of the two side support arms.

[0010] This invention also provides a method for constructing a fully prefabricated three-layer shield tunnel structure, the steps of which are as follows:

[0011] S1. Tunneling is carried out using a shield tunneling machine, and prefabricated shield segments are assembled to form a shield tunnel;

[0012] S2. Assemble the precast butterfly-shaped lower lane slab, which is transported by flatbed truck inside the shield tunnel to the assembly work area behind the shield machine.

[0013] S3. The precast butterfly-shaped lower lane slab is hoisted onto the hydraulic assembly platform and laid flat and unfolded. The precast butterfly-shaped lower lane slab and the bottom of the shield tunnel form the lower space of the tunnel structure.

[0014] S4. The precast upper lane slab is hoisted above the precast butterfly-shaped lower lane slab and inserted downwards into the fully unfolded precast butterfly-shaped lower lane slab to restrict the deformation of the precast butterfly-shaped lower lane slab and form a stable structure. At the same time, a middle space is formed between the precast upper lane slab and the precast butterfly-shaped lower lane slab, and an upper space is formed between the precast upper lane slab and the shield tunnel.

[0015] S5. Divide the tunnel into 2m to 4m sections along the tunnel's direction, repeat this process sequentially, and assemble the sections forward to achieve simultaneous construction with the tunnel boring and precast tunnel segment assembly.

[0016] Preferably, in step S3, the steel cylindrical swivel bearing is placed on a hydraulic assembly platform, the hydraulic assembly platform is equipped with a hydraulic cylinder, and the telescopic rod of the hydraulic cylinder contacts the reinforced concrete rotating arm.

[0017] Preferably, in step S3, the winch-type cable opening and closing device is opened to release the limiting cable, and at the same time, the hydraulic cylinder extension rod of the hydraulic assembly platform retracts to slowly flatten the precast butterfly-shaped lower lane slab.

[0018] The beneficial effects of this invention are:

[0019] (1) Improve the prefabrication rate and assembly rate: The tunnel structure of the present invention is composed entirely of prefabricated components, including prefabricated shield tunnel segments, prefabricated butterfly-shaped lower lane slabs and prefabricated upper lane slabs, which are fully flexibly connected, achieving a prefabrication rate and assembly rate of 100%. This avoids the use of post-cast joints in traditional construction, solves the technical problems of dust, heat of hydration and exhaust gas in the tunnel environment in the existing scheme, improves the cleanliness and safety of the construction environment, and provides healthier working conditions for workers.

[0020] (2) Improve construction efficiency: Since the present invention uses fully prefabricated components and the connection between components is simple, there is no need to pour on site and wait for concrete to harden, which can greatly improve construction efficiency; at the same time, the construction method realizes the synchronous construction with shield tunneling and shield prefabricated segment assembly, further shortening the construction period.

[0021] (3) Stable structure and strong resistance to deformation: The prefabricated butterfly-shaped lower lane slab of the present invention is unfolded and positioned by a winch-type steel cable opening and closing device and a hydraulic assembly operation platform, forming a stable lower space with the bottom of the shield tunnel. After the prefabricated upper lane slab is inserted into the prefabricated butterfly-shaped lower lane slab, its deformation is restricted, forming a more stable three-layer tunnel structure, which makes this structure have good resistance to deformation and load-bearing capacity.

[0022] (4) Easy to maintain and expand: The tunnel structure of the present invention is composed entirely of prefabricated components, so it can be easily maintained and expanded. If a component needs to be replaced or repaired, it can be removed and replaced with a new component without large-scale modification of the entire tunnel structure. Attached Figure Description

[0023] For ease of explanation, the present invention will be described in detail below with reference to specific embodiments and accompanying drawings.

[0024] Figure 1 This is a schematic diagram of the prefabricated butterfly-shaped lower lane slab in this embodiment;

[0025] Figure 2 This is a schematic diagram of the prefabricated tunnel segments assembled in this embodiment.

[0026] Figure 3 This is a schematic diagram illustrating the transportation of the prefabricated butterfly-shaped lower lane slab in a shield tunnel according to this embodiment.

[0027] Figure 4 This is a schematic diagram of the prefabricated butterfly-shaped lower lane slab placed on the hydraulic assembly platform in this embodiment;

[0028] Figure 5 This is a schematic diagram of the unfolding process of the prefabricated butterfly-shaped lower lane slab in this embodiment;

[0029] Figure 6This is a schematic diagram of the prefabricated butterfly-shaped lower lane slab after unfolding in this embodiment;

[0030] Figure 7 This is a schematic diagram of the insertion process of the prefabricated upper lane slab in this embodiment;

[0031] Figure 8 This is a schematic diagram of the overall structure after assembly in this embodiment;

[0032] Figure 9 This is a flowchart illustrating the assembly process in this embodiment.

[0033] In the picture:

[0034] 1-Precast tunnel segment; 2-Precast butterfly-shaped lower lane slab; 21-Steel column-shaped swivel bearing; 22-Steel swivel fixed arm; 23-Reinforced concrete swivel arm; 231-Bottom support arm; 232-Side support arm; 24-Wind-type steel cable opening and closing device; 25-Limiting steel cable; 3-Precast upper lane slab; 4-Hydraulic assembly platform; 5-Lower space; 6-Middle space; 7-Upper space; 8-Tunnel boring machine;

[0035] A represents the completed assembly area (horizontal transportation of precast components); B represents the assembly area of ​​the precast upper lane slab; C represents the assembly area of ​​the precast butterfly-shaped lower lane slab; D represents the unfolding area of ​​the precast butterfly-shaped lower lane slab; E represents the tunnel boring machine excavation and segment assembly area; F represents the horizontal transportation process of the precast butterfly-shaped lower lane slab; G represents the process of turning and erecting the precast butterfly-shaped lower lane slab; H represents the unfolding process of the precast butterfly-shaped lower lane slab. Detailed Implementation

[0036] The following are specific embodiments of the present invention described in conjunction with the accompanying drawings, further illustrating the technical solutions of the present invention. However, the present invention is not limited to these embodiments. Specific details, such as particular configurations and components, are provided in the following description merely to aid in a comprehensive understanding of the embodiments of the present invention. Therefore, those skilled in the art should understand that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present invention. Furthermore, for clarity and brevity, descriptions of known functions and structures have been omitted.

[0037] It should be noted that, unless otherwise specified, the embodiments and features described in this invention can be combined with each other.

[0038] like Figures 1-9As shown, this embodiment provides a fully prefabricated three-layer shield tunnel structure, including prefabricated shield segments 1, prefabricated butterfly-shaped lower lane slab 2, and prefabricated upper lane slab 3. The prefabricated shield segments 1 are assembled to form a shield tunnel. The prefabricated butterfly-shaped lower lane slab 2 can be unfolded or retracted. After unfolding, the prefabricated butterfly-shaped lower lane slab 2 is set in the middle and lower part of the shield tunnel, and forms a lower space 5 of the tunnel structure with the bottom of the shield tunnel. The lower space 5 is the equipment layer. The prefabricated upper lane slab 3 is set above the prefabricated butterfly-shaped lower lane slab 2, and forms a middle space 6 of the tunnel structure with the prefabricated butterfly-shaped lower lane slab 2. The middle space 6 is the lower lane layer. The prefabricated upper lane slab 3 and the shield tunnel form an upper space 7. The upper space 7 is the upper lane layer.

[0039] Furthermore, the precast butterfly-shaped lower lane slab 2 includes a steel column-shaped swivel bearing 21, a steel shaft fixing arm 22, a reinforced concrete swivel arm 23, a winch-type steel cable opening and closing device 24, and a limiting steel cable 25; the two reinforced concrete swivel arms 23 are symmetrically arranged, and one end of each of the two reinforced concrete swivel arms 23 is connected to the steel shaft fixing arm 22. The ends of the two steel shaft fixing arms 22 are connected by the steel column-shaped swivel bearing 21. The winch-type steel cable opening and closing device 24 is connected to the two reinforced concrete swivel arms 23 away from the steel shaft fixing arm through the limiting steel cable 25. One end of 22 is connected; the reinforced concrete rotating arm 23 includes a bottom support arm 231 and a side support arm 232, the bottom support arm 231 and the side support arm 232 are integrally formed, the outer side of the side support arm 232 is in contact with the inner side of the shield precast segment 1, and the inner side of the bottom support arm 231 is parallel to the tangent at the bottom of the shield precast segment 1 after it is unfolded; a stepped groove is provided at the end of the side support arm 232 away from the bottom support arm 231, and the precast upper lane plate 3 is inserted between the stepped grooves of the two side support arms 232.

[0040] In this embodiment, the precast butterfly-shaped lower lane slab 2 is opened by the hoisting cable opening and closing device 24, releasing the limiting cable 25. The reinforced concrete rotating arm 23 unfolds, and the bottom support arm 231 forms the lower lane structure. The side support arm 232 abuts against the shield precast segment 1. The bottom support arm 231 and the bottom of the shield tunnel form a stable lower space 5 (equipment layer) for laying cables and erecting equipment. After the precast upper lane slab 3 is inserted into the upper end of the side support arm 232 of the unfolded precast butterfly-shaped lower lane slab 2, the deformation of the precast butterfly-shaped lower lane slab 2 is restricted. The precast upper lane slab 3 and the precast butterfly-shaped lower lane slab 2 form a middle space 6 (lower lane layer), and form an upper space 7 (upper lane layer) between the precast upper lane slab 3 and the shield tunnel. This constitutes a more stable three-layer tunnel structure, which meets different traffic needs and has good deformation resistance and load-bearing capacity.

[0041] This embodiment also provides a method for constructing a fully prefabricated three-layer shield tunnel structure, the steps of which are as follows:

[0042] S1. The tunnel boring machine 8 is used for tunneling and the precast shield segments 1 are assembled to form a shield tunnel;

[0043] S2. Assemble the precast butterfly-shaped lower lane slab 2, which is transported by flatbed truck inside the shield tunnel to the assembly work area behind the shield machine 8.

[0044] S3. The precast butterfly-shaped lower lane slab 2 is hoisted onto the hydraulic assembly platform 4. The steel column-shaped rotating shaft 21 is supported on the hydraulic assembly platform 4. The hydraulic assembly platform 4 is equipped with a hydraulic cylinder. The telescopic rod of the hydraulic cylinder contacts the reinforced concrete rotating arm 23. The winch-type steel cable opening and closing device 24 is opened to release the limiting steel cable 25. At the same time, the telescopic rod of the hydraulic cylinder of the hydraulic assembly platform 4 retracts, and the precast butterfly-shaped lower lane slab 2 is slowly laid flat. The precast butterfly-shaped lower lane slab 2 and the bottom of the shield tunnel form the lower space 5 of the tunnel structure.

[0045] S4. The precast upper lane slab 3 is hoisted above the precast butterfly-shaped lower lane slab 2 and inserted downwards into the fully unfolded precast butterfly-shaped lower lane slab 2 to restrict the deformation of the precast butterfly-shaped lower lane slab 2 and form a stable structure; at the same time, a middle space 6 is formed between the precast upper lane slab 3 and the precast butterfly-shaped lower lane slab 2, and an upper space 7 is formed between the precast upper lane slab 3 and the shield tunnel.

[0046] S5. Divide the tunnel into 2m to 4m sections along the tunnel's direction, repeat this process sequentially, and assemble the sections forward to achieve simultaneous construction with the tunnel boring and precast tunnel segment assembly.

[0047] The tunnel structure in this embodiment is entirely composed of prefabricated components, including prefabricated shield tunnel segments 1, prefabricated butterfly-shaped lower lane slabs 2, and prefabricated upper lane slabs 3, all connected flexibly. This achieves a 100% prefabrication and assembly rate, avoiding the use of post-cast joints in traditional construction. It also solves the technical problems of dust, heat of hydration, and exhaust gas in the tunnel environment of existing solutions, improving the cleanliness and safety of the construction environment and providing healthier working conditions for workers. The elimination of on-site pouring and waiting for concrete to harden significantly improves construction efficiency. Furthermore, this construction method allows for simultaneous construction with shield tunneling and prefabricated shield tunnel segment assembly, further shortening the construction period.

[0048] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0049] In the description of this application, it should be understood that the terms "upper" and "lower" 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.

Claims

1. A fully precast three-layered shield tunnel structure, characterized in that, It comprises a shield prefabricated segment (1), a prefabricated butterfly-shaped lower lane plate (2) and a prefabricated upper lane plate (3); The shield prefabricated segment (1) is assembled to form a shield tunnel. The prefabricated butterfly-shaped lower lane plate (2) can be unfolded or folded, and is arranged at the middle-lower part of the shield tunnel after being unfolded, and forms a lower space (5) of the tunnel structure with the bottom of the shield tunnel, wherein the lower space (5) is a device layer. The prefabricated upper lane plate (3) is arranged above the prefabricated butterfly-shaped lower lane plate (2), and forms a middle space (6) of the tunnel structure with the prefabricated butterfly-shaped lower lane plate (2), wherein the middle space (6) is a lower lane layer. The prefabricated upper lane plate (3) and the shield tunnel form an upper space (7), and the upper space (7) is an upper lane layer. The prefabricated butterfly-shaped lower lane plate (2) comprises a steel column-shaped rotating bearing (21), a steel rotating shaft fixing arm (22), a reinforced concrete rotating arm (23), a winch-type steel cable opening and closing device (24) and a limiting steel cable (25); two reinforced concrete rotating arms (23) are symmetrically arranged, one end of each of the two reinforced concrete rotating arms (23) is connected with the steel rotating shaft fixing arm (22), the distal ends of the two steel rotating shaft fixing arms (22) are connected through the steel column-shaped rotating bearing (21), and the winch-type steel cable opening and closing device (24) is connected with one end of each of the two reinforced concrete rotating arms (23) away from the steel rotating shaft fixing arm (22) through the limiting steel cable (25). The opening of the winch-type steel cable opening and closing device (24) can drive the two reinforced concrete rotating arms (23) to unfold or fold.

2. A fully precast three-layered shield tunnel structure according to claim 1, characterized in that, The reinforced concrete rotating arm (23) comprises a bottom support arm (231) and a side support arm (232), the bottom support arm (231) and the side support arm (232) are integrally formed, the outer side of the side support arm (232) is attached to the inner side of the shield prefabricated segment (1), and the inner side of the bottom support arm (231) is parallel to the tangent line of the bottom of the shield prefabricated segment (1) after unfolding.

3. A fully precast three-layered shield tunnel structure according to claim 2, characterized in that, The end of the side support arm (232) away from the bottom support arm (231) is provided with a stepped groove, and the prefabricated upper lane plate (3) is inserted between the stepped grooves of the two side support arms (232).

4. A method of constructing a fully precast three-layered shield tunnel structure according to any one of claims 2-3, characterized in that, The steps are as follows: S1, a shield tunnel is formed by using a shield machine to carry out tunneling construction and assembling shield prefabricated segments (1); S2, the prefabricated butterfly-shaped lower lane plate (2) is assembled and transported by a flat car to the rear of the shield machine (8) in the shield tunnel for assembly operation; S3, the prefabricated butterfly-shaped lower lane plate (2) is hoisted to the hydraulic assembly operation platform (4), and the prefabricated butterfly-shaped lower lane plate (2) is laid flat and unfolded, and the prefabricated butterfly-shaped lower lane plate (2) and the bottom of the shield tunnel form a lower space (5) of the tunnel structure; S4, the prefabricated upper lane plate (3) is hoisted to the prefabricated butterfly-shaped lower lane plate (2), and is inserted into the fully expanded prefabricated butterfly-shaped lower lane plate (2) downward, so that the prefabricated butterfly-shaped lower lane plate (2) is limited to be deformed, a stable structure is formed, meanwhile, a middle layer space (6) is formed between the prefabricated upper lane plate (3) and the prefabricated butterfly-shaped lower lane plate (2), and an upper layer space (7) is formed between the prefabricated upper lane plate (3) and the shield tunnel; S5, the shield tunnel is divided into 2m~4m pieces along the direction, and the pieces are repeated and assembled in sequence, so that the synchronous construction with the shield tunneling and the shield prefabricated segment assembly is realized.

5. A method of constructing a fully precast three-layered shield tunnel structure according to claim 4, wherein, In step S3, the steel column-shaped rotating bearing (21) is placed on the hydraulic assembly operation platform (4), and the hydraulic assembly operation platform (4) is provided with a hydraulic cylinder, and the telescopic rod of the hydraulic cylinder is in contact with the reinforced concrete rotating arm (23).

6. A method of constructing a fully precast three-layered shield tunnel structure according to claim 5, wherein, In step S3, the winch type steel cable opening and closing device (24) is opened, the limiting steel cable (25) is released, and the telescopic rod of the hydraulic cylinder of the hydraulic assembly operation platform (4) is retracted, so that the prefabricated butterfly-shaped lower lane plate (2) is slowly flattened.

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