Tunneling roadway bottom plate hardening mold and method

Abstract

The invention relates to the field of roadway excavation, and provides an excavation roadway bottom plate hardening mold and method. The excavation roadway bottom plate hardening mold comprises a left fence and a right fence which form a main body structure of the mold and are used for limiting a concrete pouring area. The longitudinal rib supporting beams are arranged on the left fence and the right fence; and the pedestrian pedals are laid on the longitudinal rib supporting beams and used for forming a pedestrian passage during hardening construction of the roadway bottom plate. The tunneling roadway bottom plate hardening mold is simple in structure, convenient to disassemble and assemble, capable of being erected and disassembled in a segmented mode according to the tunneling progress, adaptive to the construction characteristic of gradual forming of a roadway, capable of improving the joint collaboration among all working procedures and capable of shortening the forming time of the roadway. According to the overall design, construction convenience, traffic safety and pavement hardening quality are considered, the problems that in traditional hardening operation, cleaning difficulty is large, a safety channel is occupied, and the material storage pressure is large are effectively solved, and rapid forming of a tunneling roadway is promoted.

Description

Technical Field

[0001] This invention relates to the field of tunnel excavation, and provides a mold and method for hardening the floor slab of a tunnel. Background Technology

[0002] With the continuous improvement of mechanization in coal mines, the daily tunneling volume at the working face is constantly increasing, putting enormous pressure on the transportation and transfer of materials in the mine. In traditional mining operations, to improve transportation efficiency and safety, as well as the working environment, mines typically harden the road surface. There are two specific methods for road surface hardening: one is to harden the roadway in a concentrated manner after it is formed. However, due to factors such as personnel transportation and roadway cleaning, the roadway often becomes dirty and messy due to water accumulation and mud, increasing the difficulty of the initial cleaning work; the other is to harden the road surface gradually during tunneling. While this method can reduce the pressure of road surface cleaning, it increases the pressure on on-site material storage and occupies important safety passages. Therefore, when conditions permit, mines usually choose to harden the road surface in a concentrated manner after the roadway is formed. However, if the floor conditions are poor, the road surface must be hardened gradually during tunneling. In this case, a half-width hardening method is usually adopted.

[0003] In the development of fully mechanized mines, to address the various problems caused by road surface hardening, mines, once conditions permit, will adopt a method of gradually hardening the road surface during tunneling. This method can reduce the dirtiness of the road surface and improve the quality of the working environment to some extent. However, because it requires continuous paving and hardening of the road surface during tunneling, it increases the on-site dependence on tunneling equipment and materials, and may also affect the continuity of tunneling work and the use of safe passages to some extent.

[0004] In conclusion, hardening mine road surfaces not only improves transportation efficiency and safety but is also an important means of improving the working environment. However, different geological conditions and levels of mechanization require mines to comprehensively consider various factors and select the most suitable hardening scheme when adopting road surface hardening technology to ensure efficient and safe coal mine production. Summary of the Invention

[0005] This invention provides a mold for hardening the floor slab of a tunnel, which solves the problem of difficulty in the later hardening processes of tunnel cleaning and floor slab leveling due to untimely hardening of the tunnel surface.

[0006] This invention also provides a method for hardening the floor slab of a tunnel.

[0007] A first aspect of the present invention provides a mold for hardening the floor slab of a tunnel, comprising: Left and right enclosures, which constitute the main structure of the mold and are used to define the concrete pouring area; Longitudinal rib support beams are provided on the left and right enclosures; Pedestrian treads, which are laid on the longitudinal rib support beams, are used to form a pedestrian passage during the hardening construction of the tunnel floor.

[0008] According to one embodiment of the present invention, the left and right enclosures are composed of a lower concrete enclosure and an upper supporting beam; The lower part of the concrete enclosure is used to block the concrete. The upper part of the support beam is used to support the longitudinal rib support beam.

[0009] According to one embodiment of the present invention, the height of the upper support beam is higher than the height of the lower concrete enclosure, and the difference between the height of the upper support beam and the height of the lower concrete enclosure ranges from 100 mm to 200 mm, so as to form an operating space for pouring, vibration, finishing and roughening operations.

[0010] According to one embodiment of the present invention, the front and rear ends of the left and right enclosures are connected by a pin structure to achieve longitudinal extension of the mold.

[0011] According to one embodiment of the present invention, the mold further includes front and rear auxiliary ramps; The front and rear auxiliary ramps are connected to the ends of the pedestrian treads to achieve a smooth transition between the pedestrian passage and the alleyway floor.

[0012] A second aspect of the present invention provides a method for hardening the floor slab of a tunnel using the aforementioned tunnel floor hardening mold, comprising: After the tunneling machine, self-propelled tail section, or anchor bolt trolley pulls the tail section to the new fixed location, the pre-hardened location is cleaned and leveled. The hardened mold for the tunnel floor slab of the first stage is removed and transported to the third stage to complete the mold erection; The road surface hardening operation is carried out within the mold in the three stages, including pouring, vibration, finishing and roughening; After the road surface hardening work is completed, the pedestrian treads are placed over the longitudinal rib support beams to restore the pedestrian walkway.

[0013] According to one embodiment of the present invention, the mold erection step specifically includes: When initially erecting the first-stage mold, ground anchors are set up to assist in the mold erection; When setting up the formwork later, the concrete from the previous stage is used as a stable foundation for the formwork.

[0014] According to one embodiment of the present invention, the step of removing the hardened mold for the floor slab of the tunnel in the first stage further includes: Remove the pedestrian treads mentioned in the second phase; After the road surface hardening work is completed, the removed pedestrian treads from the second stage are used for covering.

[0015] According to one embodiment of the present invention, in the road hardening operation, the workers lay one longitudinal rib support beam after each longitudinal rib distance of concrete foundation pouring is completed; after all the longitudinal rib support beams are laid and all hardening operations are completed, the pedestrian treads are laid.

[0016] According to one embodiment of the present invention, the objective of the cleaning operation is to clean up small-scale water accumulation, coal sludge, and scattered residual coal dust.

[0017] According to the first aspect of the present invention, the tunnel floor hardening mold precisely defines the concrete pouring area with left and right barriers, preventing concrete from spreading and wasting during pouring, ensuring a neat and uniform hardened pavement boundary, and improving the quality of the tunnel pavement hardening. The rigid structure and tight-fitting installation of the barriers effectively block the lateral pressure of the concrete, preventing mold displacement during pouring and ensuring the straightness and flatness of the hardened pavement. No additional complex fixing structure is required; the material-blocking function can be achieved solely through its own design, simplifying the mold structure and reducing the difficulty of erection. The longitudinal rib support beams construct a stable transverse support frame, providing uniform and reliable support points for pedestrian treads, ensuring that the treads can withstand the weight of workers and small materials, preventing tread deformation or collapse, and ensuring passage safety. The uniform spacing design of the support beams, while meeting load-bearing requirements, reserves operating space for vibration and finishing operations after concrete pouring, allowing for refined construction without dismantling the support structure, improving operational convenience. The synergistic effect of the support beams and the left and right barriers enhances the overall stability of the mold, preventing damage caused by excessive stress on a single component and extending the mold's service life. After the pedestrian treads are laid, a continuous pedestrian walkway is formed, resolving the conflict between the construction area and the passageway in traditional tunnel hardening operations. This allows hardening work to proceed simultaneously with normal tunnel passage, without affecting daily operations such as the transfer of tunneling equipment and personnel movement, ensuring the continuity of tunneling work. The anti-slip and wear-resistant design of the treads is suitable for the harsh environment of dampness and dust underground, reducing the risk of slipping for workers and improving construction safety. The quick-assembly and disassembly of the treads facilitates mold reuse, reduces pressure on on-site material reserves, lowers construction costs, and facilitates timely subsequent maintenance after pouring. The integrated mold, composed of these three elements, achieves multiple functions: limiting the pouring area, supporting the passageway, and ensuring operational safety. It eliminates the need for additional temporary passages, simplifying the construction process of hardening the tunnel floor. The mold structure is simple and easy to assemble and disassemble. It can be erected and dismantled in sections according to the tunneling progress, adapting to the gradual formation of the tunnel and improving the coordination between various tunnel forming processes, thus shortening the tunnel forming time. The overall design takes into account the ease of construction, traffic safety, and the quality of road hardening, effectively solving problems such as the difficulty of cleaning, occupation of safety passages, and high pressure on material reserves in traditional hardening operations, and promoting the rapid formation of tunnels.

[0018] According to the second aspect of the present invention, the method for hardening the floor slab of a tunnel includes a cleaning operation that specifically removes contaminants affecting the hardening quality, preventing weak bonding between the concrete and the floor slab, hollow areas, or cracks, and improving the durability of the hardened pavement. The leveling operation provides a uniform stress base for concrete pouring, ensuring consistent thickness and high flatness of the hardened pavement, meeting the needs of tunnel transportation and passage. These two operations are carried out simultaneously with the tail-end alignment and leveling process, making full use of construction gaps without additional time commitment to the tunneling cycle, improving overall construction efficiency, preventing water accumulation and mud buildup due to prolonged unhardened tunnels, and reducing the difficulty of later cleaning. Mold reuse reduces pressure on on-site material reserves, lowers equipment investment costs, and avoids transportation and storage difficulties caused by setting up a large number of molds at once. Sequential mold removal ensures component integrity and extends mold lifespan; molds are erected based on the previous stage of concrete, simplifying the fixing process, eliminating the need for complex additional fixing structures, improving erection efficiency, and ensuring accurate mold positioning for a continuous, regular, and smooth hardened pavement. Ground anchors assist in initial erection to ensure mold stability, preventing mold displacement during pouring due to a soft floor slab, and ensuring hardening quality. The method of simultaneously pouring and installing longitudinal rib support beams ensures a tight bond between the support beams and the concrete, enhancing the stability of the support frame and initially compacting the concrete, reducing air bubbles and improving pavement density. The continuous process of vibration, finishing, and roughening ensures the hardened pavement meets quality standards, resulting in a smooth surface with good anti-slip properties, satisfying underground traffic safety requirements. All detailed operations can be completed without removing the molds, simplifying the construction process, improving efficiency, and avoiding delays caused by repeated mold disassembly and reassembly in traditional methods. Pedestrian walkways are immediately restored after hardening, resolving the issue of construction areas obstructing safety passages in traditional hardening operations, ensuring the normal operation of daily tasks such as transporting tunneling equipment and personnel, and ensuring the continuity of tunneling work. Traffic can proceed without waiting for the concrete to fully cure, making full use of construction breaks to advance hardening work, shortening the time before the tunnel floor hardens, and reducing the impact of water accumulation and mud on the working environment. The rapid laying of pedestrian treads, combined with the load-bearing capacity of the molds, protects the concrete surface from damage caused by traffic, while also providing protection for concrete curing, further improving the quality of the hardened pavement. This method, through synchronized processes and reusable molds, achieves coordinated advancement of tunneling and floor hardening operations, effectively solving problems such as high cleaning difficulty, obstruction of safety passages, and heavy material reserve pressure in traditional hardening methods. Phased hardening allows the tunnel floor to gradually take shape as tunneling progresses, avoiding large-scale cleaning work during later concentrated hardening, thus reducing construction difficulty and labor intensity. The adaptive design of the molds and method ensures that the hardened road surface meets standards and guarantees safe passage, while simultaneously improving overall construction efficiency, accelerating the formation of tunnels, enhancing the tunnel's material transfer capacity, and reducing the need for manpower and material reserves. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic perspective view of the tunnel floor hardening mold provided by the present invention.

[0021] Figure 2 This is a schematic layout diagram of the alleyway space provided by the present invention.

[0022] Figure 3 This is a schematic diagram of the tunnel space provided by the present invention.

[0023] Figure 4 This is a schematic flowchart of the method for hardening the floor of a tunnel provided by the present invention.

[0024] Figure label: 100. Left and right side barriers; 102. Longitudinal rib support beams; 104. Pedestrian steps; 106. Front and rear auxiliary ramps. Detailed Implementation

[0025] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0026] like Figures 1 to 3 As shown, a first aspect of the present invention provides a mold for hardening the floor slab of a tunnel, comprising: The left and right enclosures form the main structure of the mold and are used to define the concrete pouring area. Longitudinal rib support beams are installed on the left and right enclosures. Pedestrian treads are laid on the longitudinal rib support beams to form pedestrian passages during the hardening construction of the tunnel floor.

[0027] According to the first aspect of the present invention, the tunnel floor hardening mold precisely defines the concrete pouring area with left and right barriers, preventing concrete from spreading and wasting during pouring, ensuring a neat and uniform hardened pavement boundary, and improving the quality of the tunnel pavement hardening. The rigid structure and tight-fitting installation of the barriers effectively block the lateral pressure of the concrete, preventing mold displacement during pouring and ensuring the straightness and flatness of the hardened pavement. No additional complex fixing structure is required; the material-blocking function can be achieved solely through its own design, simplifying the mold structure and reducing the difficulty of erection. The longitudinal rib support beams construct a stable transverse support frame, providing uniform and reliable support points for pedestrian treads, ensuring that the treads can withstand the weight of workers and small materials, preventing tread deformation or collapse, and ensuring passage safety. The uniform spacing design of the support beams, while meeting load-bearing requirements, reserves operating space for vibration and finishing operations after concrete pouring, allowing for refined construction without dismantling the support structure, improving operational convenience. The synergistic effect of the support beams and the left and right barriers enhances the overall stability of the mold, preventing damage caused by excessive stress on a single component and extending the mold's service life. After the pedestrian treads are laid, a continuous pedestrian walkway is formed, resolving the conflict between the construction area and the passageway in traditional tunnel hardening operations. This allows hardening work to proceed simultaneously with normal tunnel passage, without affecting daily operations such as the transfer of tunneling equipment and personnel movement, ensuring the continuity of tunneling work. The anti-slip and wear-resistant design of the treads is suitable for the harsh environment of dampness and dust underground, reducing the risk of slipping for workers and improving construction safety. The quick-assembly and disassembly of the treads facilitates mold reuse, reduces pressure on on-site material reserves, lowers construction costs, and facilitates timely subsequent maintenance after pouring. The integrated mold, composed of these three elements, achieves multiple functions: limiting the pouring area, supporting the passageway, and ensuring operational safety. It eliminates the need for additional temporary passages, simplifying the construction process of hardening the tunnel floor. The mold structure is simple and easy to assemble and disassemble. It can be erected and dismantled in sections according to the tunneling progress, adapting to the gradual formation of the tunnel and improving the coordination between various tunnel forming processes, thus shortening the tunnel forming time. The overall design takes into account the ease of construction, traffic safety, and the quality of road hardening, effectively solving problems such as the difficulty of cleaning, occupation of safety passages, and high pressure on material reserves in traditional hardening operations, and promoting the rapid formation of tunnels.

[0028] Please continue reading Figures 1 to 3 The tunnel floor hardening mold provided in the first aspect of the present invention mainly includes left and right barriers, longitudinal rib support beams and pedestrian treads.

[0029] The left and right side barriers, serving as the main load-bearing structures of the mold, are made of rigid materials and are symmetrically arranged on both sides of the pre-designated concrete pouring area on the tunnel floor. The length of the barriers is matched to the length of the tunnel in a single hardening operation, and their height is precisely matched to the concrete pouring thickness, ensuring effective prevention of concrete overflow to both sides during pouring and accurately limiting the pouring range. The bottom of the barriers fits tightly against the tunnel floor, and their own weight and subsequent auxiliary fixing structures ensure stable placement without shaking or displacement.

[0030] The longitudinal rib support beams are rigid beams arranged laterally, made of the same material as the left and right fencing, and possess sufficient load-bearing strength. The longitudinal rib support beams are evenly spaced along the length of the left and right fencing, with both ends resting on top of the fencing, closely fitting the support surface at the top of the fencing to form a stable transverse support frame. The spacing of the support beams has been optimized to ensure uniform support for the pedestrian walkways without interfering with post-concrete compaction and finishing operations.

[0031] The pedestrian treads are flat and made of non-slip, wear-resistant rigid materials. The treads are sized to fit the spacing of the longitudinal rib support beams, completely covering the space between adjacent support beams. The treads are laid flat on top of the longitudinal rib support beams, with tight joints between the treads, forming a continuous pedestrian passage. The treads are laid in the same direction as the length of the aisle, facilitating the passage of workers and small materials along the aisle's length. Furthermore, the treads can be quickly installed and dismantled, facilitating reuse.

[0032] When assembling the mold, first locate and fix the left and right barriers according to the size of the hardened area to ensure that the barriers are parallel and the spacing is uniform; then, erect the longitudinal rib support beams on the top of the barriers in sequence, adjust the spacing and fix them; finally, lay the pedestrian treads to complete the erection of the entire mold. The overall structure is easy to assemble and disassemble, and can be constructed in sections and reused according to the progress of tunneling.

[0033] According to one embodiment of the present invention, the left and right enclosures are composed of a lower half of concrete enclosures and an upper half of supporting beams; The lower part of the concrete enclosure is used to block the concrete. The upper part of the support beam is used to support the longitudinal rib support beam.

[0034] In one embodiment of the invention, the left and right barriers adopt a segmented structure: the lower part is a concrete barrier, made of hard and wear-resistant material, with a height adapted to the concrete pouring thickness, directly contacting the tunnel floor slab and playing a core role in blocking the concrete. The upper part is a support beam, made of rigid material, fixedly connected to the top of the concrete barrier, forming an integrated structure with the concrete barrier. The top of the support beam is a flat support surface for placing longitudinal rib support beams, and its structural strength meets the bearing requirements of pedestrian steps and traffic loads. The upper and lower parts are fixed by a reliable connection method to ensure overall stability and avoid relative displacement during construction.

[0035] Concrete barriers, through their own weight and rigidity, effectively prevent lateral flow of concrete, ensuring uniform thickness and clear boundaries of the hardened pavement. The upper support beam is specifically designed to accommodate the installation of longitudinal rib support beams, enhancing support stability, preventing pedestrian walkways from swaying or collapsing, and ensuring passage safety. The segmented structural design allows the barriers to function as both retaining and supporting structures, eliminating the need for additional support components, simplifying the mold structure, and reducing manufacturing costs. Concrete barriers are wear-resistant and corrosion-resistant, adapting to the harsh underground environment, extending the service life of the molds, and the rigid design of the support beams ensures load-bearing capacity, meeting the requirements for long-term repeated use.

[0036] According to one embodiment of the present invention, the height of the upper support beam is higher than the height of the lower concrete enclosure, and the difference between the height of the upper support beam and the height of the lower concrete enclosure ranges from 100 mm to 200 mm, so as to form an operating space for pouring, vibration, finishing and roughening operations.

[0037] In one embodiment of the invention, the height of the upper support beam is higher than the height of the lower concrete enclosure, creating a height difference that constitutes the operating space. This operating space is continuously distributed along the length of the pouring area, with a width consistent with the width of the pouring area between the left and right enclosures, sufficient for workers to reach in for pouring, vibration, finishing, and roughening operations. The height design of the support beam ensures that the size of the operating space is adapted to construction needs, facilitating the entry and exit of workers' hands and tools without affecting the installation of the longitudinal rib support beams or the stability of the pedestrian walkway. The height of the concrete enclosure precisely matches the concrete pouring thickness, avoiding excessively thick or thin pours.

[0038] The reserved operating space allows workers to complete a series of delicate operations after concrete pouring without dismantling the formwork, improving construction convenience and the quality of the hardened pavement, and avoiding the cumbersome process of repeated disassembly and adjustment required by traditional formwork. The continuous distribution of the operating space ensures that the hardening operation can proceed continuously, improving construction efficiency. The height difference design between the support beam and the concrete enclosure meets operational needs without increasing the space occupied by formwork, balancing construction convenience and passageway efficiency, and further optimizing the coordination between hardening operations and tunnel operation.

[0039] According to one embodiment of the present invention, the front and rear ends of the left and right enclosures are connected by a pin structure to achieve longitudinal extension of the mold.

[0040] In one embodiment of the invention, the front and rear ends of the left and right enclosures are respectively provided with matching pin and slot structures. When it is necessary to extend the mold length to accommodate a longer hardened tunnel area, the pin of the front enclosure is inserted into the slot of the rear enclosure, and the two enclosures are fixedly connected through the tight fit between the pin and the slot. During connection, ensure that the connection positions of the left and right enclosures are aligned so that the casting area extends in a straight line. The overall structure after connection is stable and free from loosening or displacement. The pin structure is easy to assemble and disassemble, requiring no additional tools, and allows for quick longitudinal splicing and disassembly of the mold.

[0041] The pin structure allows for flexible longitudinal extension of the mold, adapting to the hardening requirements of tunnels of varying lengths and enhancing its versatility. Its rapid assembly and disassembly capabilities enable the mold to be erected in sections according to the tunneling progress, avoiding transportation and installation difficulties caused by erecting excessively long sections at once. The connected retaining structure is stable, ensuring no displacement due to concrete lateral pressure during pouring, guaranteeing a continuous and regular hardened road surface. The pin structure experiences minimal wear and can be reused multiple times, reducing mold maintenance costs and further improving construction efficiency.

[0042] According to one embodiment of the present invention, the mold further includes front and rear auxiliary ramps; The front and rear auxiliary ramps are connected to the ends of the pedestrian treads to achieve a smooth transition between the pedestrian passage and the alleyway floor.

[0043] In one embodiment of the invention, the front and rear auxiliary ramps are wedge-shaped structures made of the same rigid material as the pedestrian treads and are installed at both ends of the pedestrian walkway. One end of the ramp overlaps the end of the pedestrian tread, while the other end conforms to the unpaved ground of the alleyway, forming a smooth transition surface. The ramps are designed with a gentle slope, suitable for workers to walk and small carts to pass through. The surface is equipped with an anti-slip structure to improve safety in wet environments. The ramps and pedestrian treads are detachably connected, facilitating disassembly during mold transfer without affecting overall assembly and disassembly efficiency.

[0044] The gentle slope eliminates the height difference between the pedestrian walkway and the tunnel floor, preventing tripping risks and improving the safety and convenience of the passageway, meeting the needs of frequent workers. The gentle slope design reduces the difficulty of transporting small materials, facilitating the transfer of construction tools and materials and improving work efficiency. The anti-slip structure enhances stability, adapting to the damp and dusty underground environment and reducing safety hazards. The detachable design of the slope does not affect the disassembly, assembly, and transfer of molds, further enhancing the practicality and flexibility of the molds.

[0045] See Figure 4A second aspect of the present invention provides a method for hardening the floor slab of a tunnel using the aforementioned tunnel floor hardening mold, comprising: Step 10: After the tunneling machine, self-propelled tail section, or anchor bolt trolley pulls the tail section to the new fixed location, clean and level the pre-hardened location. Step 20: Remove the hardened mold of the tunnel floor slab in the first stage and transfer it to the third stage to complete the mold erection. Step 30: The road surface hardening operation is carried out in the three-stage mold, including pouring, vibration, finishing and roughening; Step 40: After the road surface hardening work is completed, cover the pedestrian treads on the longitudinal rib support beams to restore the pedestrian walkway.

[0046] According to the second aspect of the present invention, the method for hardening the floor slab of a tunnel includes a cleaning operation that specifically removes contaminants affecting the hardening quality, preventing weak bonding between the concrete and the floor slab, hollow areas, or cracks, and improving the durability of the hardened pavement. The leveling operation provides a uniform stress base for concrete pouring, ensuring consistent thickness and high flatness of the hardened pavement, meeting the needs of tunnel transportation and passage. These two operations are carried out simultaneously with the tail-end alignment and leveling process, making full use of construction gaps without additional time commitment to the tunneling cycle, improving overall construction efficiency, preventing water accumulation and mud buildup due to prolonged unhardened tunnels, and reducing the difficulty of later cleaning. Mold reuse reduces pressure on on-site material reserves, lowers equipment investment costs, and avoids transportation and storage difficulties caused by setting up a large number of molds at once. Sequential mold removal ensures component integrity and extends mold lifespan; molds are erected based on the previous stage of concrete, simplifying the fixing process, eliminating the need for complex additional fixing structures, improving erection efficiency, and ensuring accurate mold positioning for a continuous, regular, and smooth hardened pavement. Ground anchors assist in initial erection to ensure mold stability, preventing mold displacement during pouring due to a soft floor slab, and ensuring hardening quality. The method of simultaneously pouring and installing longitudinal rib support beams ensures a tight bond between the support beams and the concrete, enhancing the stability of the support frame and initially compacting the concrete, reducing air bubbles and improving pavement density. The continuous process of vibration, finishing, and roughening ensures the hardened pavement meets quality standards, resulting in a smooth surface with good anti-slip properties, satisfying underground traffic safety requirements. All detailed operations can be completed without removing the molds, simplifying the construction process, improving efficiency, and avoiding delays caused by repeated mold disassembly and reassembly in traditional methods. Pedestrian walkways are immediately restored after hardening, resolving the issue of construction areas obstructing safety passages in traditional hardening operations, ensuring the normal operation of daily tasks such as transporting tunneling equipment and personnel, and ensuring the continuity of tunneling work. Traffic can proceed without waiting for the concrete to fully cure, making full use of construction breaks to advance hardening work, shortening the time before the tunnel floor hardens, and reducing the impact of water accumulation and mud on the working environment. The rapid laying of pedestrian treads, combined with the load-bearing capacity of the molds, protects the concrete surface from damage caused by traffic, while also providing protection for concrete curing, further improving the quality of the hardened pavement. This method, through synchronized processes and reusable molds, achieves coordinated advancement of tunneling and floor hardening operations, effectively solving problems such as high cleaning difficulty, obstruction of safety passages, and heavy material reserve pressure in traditional hardening methods. Phased hardening allows the tunnel floor to gradually take shape as tunneling progresses, avoiding large-scale cleaning work during later concentrated hardening, thus reducing construction difficulty and labor intensity. The adaptive design of the molds and method ensures that the hardened road surface meets standards and guarantees safe passage, while simultaneously improving overall construction efficiency, accelerating the formation of tunnels, enhancing the tunnel's material transfer capacity, and reducing the need for manpower and material reserves.

[0047] Please continue reading Figure 4The method for hardening the floor slab of a tunnel provided in the second aspect of the present invention mainly includes: Step 10: Cleaning and leveling the pre-designed hardening area Once the tunneling machine, self-propelled tail section, or bolting trolley tows the tail section to the new fixed location, a portion of the workforce is immediately dispatched to the pre-designated hardening area to carry out operations while the alignment and leveling of the entire tail section is being conducted simultaneously. The cleaning operation aims to remove small amounts of accumulated water, coal sludge, and loose coal dust, using simple tools to quickly remove debris and prevent contaminants from contaminating the subsequent concrete and affecting the hardening quality. The leveling operation involves manual trimming to smooth the roadway floor in the pre-designated hardening area, eliminating obvious protrusions, depressions, and abrupt slopes to ensure uniform stress on the floor and provide a flat foundation for concrete pouring. Both operations are completed simultaneously without additional tunneling time.

[0048] Step 20: Mold dismantling, transportation, and erection While the clearing and leveling work was underway, another group of workers dismantled the hardened formwork for the first-stage tunnel floor slab, which had already undergone hardening and curing. The dismantling process proceeded in the order of pedestrian walkways, longitudinal rib support beams, and left and right retaining walls to avoid damage to the formwork from forceful dismantling. The dismantled formwork components were then categorized and transported to the pre-designated hardened area for the third stage, taking care to prevent collisions and deformation during transport. When erecting the formwork, ground anchors were initially used to secure the first-stage formwork, ensuring its stability. When erecting the third-stage formwork, the already hardened concrete pavement of the previous stage served as a stable foundation. The left and right retaining walls were symmetrically arranged on both sides of the pre-designated hardened area to precisely define the pouring range. Longitudinal rib support beams were then evenly distributed along the length of the retaining walls, ensuring that both ends of the support beams were tightly fitted to the retaining walls to form a stable support frame.

[0049] Step 30: Implementation of road surface hardening work After the formwork is erected, workers pour concrete into the designated pouring area defined by the left and right barriers. The pouring process is continuous and uniform, avoiding any missed pours or localized accumulation. After each section of concrete is poured at intervals equal to the longitudinal rib support beams, a longitudinal rib support beam is immediately placed and pressed into place, ensuring a tight bond between the support beam and the concrete. Once all concrete has been poured and the longitudinal rib support beams are in place, the concrete is vibrated to remove air bubbles and ensure density. Then, finishing work is carried out to make the concrete surface smooth and flat, meeting the requirements for road surface use. Finally, a roughening treatment is applied to enhance the road surface's anti-slip properties and improve traffic safety.

[0050] Step 40: Pedestrian walkway restored After the road surface hardening work (pouring, vibration, finishing, and roughening) is completed, there is no need to wait for the concrete to fully cure. Immediately, the previously removed second-stage pedestrian treads or spare pedestrian treads are laid flat on the longitudinal rib support beams. The treads are tightly joined without obvious gaps, forming a continuous and unobstructed pedestrian passage. After the passage is restored, the workers leave the work area to ensure that normal passage in the alley is not affected. The mold and the hardened road surface share the traffic load until the concrete is fully cured and formed.

[0051] According to one embodiment of the present invention, the mold erection step specifically includes: When initially erecting the first-stage mold, ground anchors are set up to assist in the mold erection. When setting up the formwork later, the concrete from the previous stage is used as a stable foundation for the formwork.

[0052] In one embodiment of the invention, the mold erection steps are optimized according to the construction stages: When initially erecting the first-stage mold, since there is no stable supporting foundation around it, ground anchors are set on the outside of the left and right enclosures. The ground anchors penetrate into the tunnel floor and are fixed to the left and right enclosures through connectors, enhancing the overall stability of the mold and preventing the mold from shifting during the pouring process. When erecting the second-stage, third-stage, and other molds, the hardened concrete pavement of the previous stage is used as a stable foundation. The bottom of the left and right enclosures is placed against the edge of the hardened pavement, without the need for additional ground anchors. The constraint of the concrete pavement ensures accurate mold positioning, making the erection process quick and convenient.

[0053] Initially, ground anchors ensure mold stability, preventing displacement due to a soft base and guaranteeing the quality of the first section of hardened pavement. Subsequent use of hardened concrete as a foundation simplifies the erection process, reduces ground anchor installation steps, and saves time and labor costs. Precise mold positioning ensures smooth transitions between hardened pavement sections and high overall flatness. This design adapts to the dynamic construction characteristics of tunnel excavation, improving mold erection efficiency and further ensuring that hardening operations and excavation progress simultaneously.

[0054] According to one embodiment of the present invention, the step of removing the hardened mold for the floor slab of a first-stage tunnel further includes: Remove the second phase of pedestrian treads; After the road surface hardening work is completed, the removed second-stage pedestrian treads will be used for covering.

[0055] In one embodiment of the present invention, the mold reuse process is as follows: After the first-stage hardened pavement is cured, the left and right barriers and longitudinal rib support beams of the first stage are removed, and the pedestrian treads of the second stage, which have completed their passage function, are also removed. The dismantled first-stage mold components are transported to the third-stage erection, and the dismantled second-stage pedestrian treads are temporarily stored for later use. After the third-stage pavement hardening operation (pouring, vibration, finishing, and roughening) is completed, the spare second-stage pedestrian treads are immediately placed on the longitudinal rib support beams of the third stage, quickly restoring the pedestrian passage of the third stage. This allows passage to be met without waiting for the concrete to fully cure.

[0056] The reuse of pedestrian treads reduces the number of treads used, lowers the pressure and cost of material reserves, and avoids resource waste. After hardening work is completed, the treads are immediately covered to restore the passageway, shortening the interruption time, ensuring the continuity of passage in the tunnel, and improving overall construction efficiency. Passage can be made without waiting for the concrete to fully cure, making full use of construction gaps, promoting the coordinated progress of hardening and tunneling operations, further reducing the time unhardened areas in the tunnel exist, and lowering the risk of water accumulation and mud.

[0057] According to one embodiment of the present invention, during the road hardening operation, the workers lay a longitudinal rib support beam after each longitudinal rib distance of concrete foundation pouring is completed; after all longitudinal rib support beams are laid and all hardening operations are completed, pedestrian treads are laid.

[0058] In one embodiment of the present invention, the construction process for road hardening is optimized as follows: After the mold is erected, workers pour concrete into the area defined by the left and right barriers. After each section of concrete is poured with a spacing equal to that of the longitudinal rib support beams, a longitudinal rib support beam is immediately erected on the left and right barriers, and pressed down to ensure the bottom of the support beam contacts the concrete, guaranteeing its secure positioning. This process is repeated until all concrete pouring and longitudinal rib support beam placement are completed, followed by vibration, surface finishing, and roughening. After surface treatment, pedestrian walkways are laid flat on the longitudinal rib support beams, completing the pedestrian walkway construction.

[0059] Simultaneous pouring and installation of longitudinal rib support beams ensures a tight bond between the beams and the concrete, enhancing the stability of the support structure. The support beams also provide initial compaction of the concrete. Timely installation of the longitudinal rib support beams prevents deformation of the concrete before initial setting, ensuring the smoothness of the hardened pavement. The entire process is seamlessly integrated, reducing construction waiting time and improving the efficiency of the hardening operation. Pedestrian treads are laid immediately after surface treatment, quickly restoring the passageway and preventing contamination or damage to the concrete surface, thus guaranteeing the quality of the hardened pavement.

[0060] According to one embodiment of the present invention, the objective of the cleaning operation is to remove small-scale accumulated water, coal sludge, and scattered residual coal dust.

[0061] In one embodiment of the invention, the cleaning operation mainly targets small-scale water accumulation, coal sludge, and scattered residual coal dust, which are quickly removed using simple tools. The leveling operation involves manual trimming to ensure a gentle slope on the roadway floor, without obvious protrusions or depressions, meeting the requirements for concrete foundation pouring. The two processes are carried out simultaneously; the cleaning and leveling operations are completed at the same time as the tail end alignment and leveling, allowing time for subsequent formwork erection and hardening operations.

[0062] Timely removal of small-scale water accumulation and coal sludge to prevent seepage into the foundation or formation of mud reduces the difficulty of leveling, ensures the quality of the hardened foundation, and improves the durability of the hardened pavement. Reasonable division of labor among workers avoids manpower waste, improves construction organization efficiency, and promotes the simultaneous conduct of tunneling and hardening operations.

[0063] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A roadway floor hardening mold comprising, The utility model relates to a tunnel construction technology field, and particularly relates to a tunnel construction method and a tunnel construction mold. Comprise: Left and right fences, which constitute the main structure of the mold, are used to define the concrete pouring area; Longitudinal rib support beams are arranged on the left and right fences; 2. The tunneling roadway floor hardening mold of claim 1, wherein, Pedestrian walkways are formed on the longitudinal rib support beams during the roadway floor hardening construction. The left and right fences are composed of a lower half concrete fence and an upper half support beam; The lower half concrete fence is used to block the concrete; 3. The tunneling roadway floor hardening mold of claim 2, wherein, The upper half support beam is used to support the longitudinal rib support beams.

4. The tunneling roadway floor hardening mold of claim 1, wherein, The height of the upper half support beam is higher than the height of the lower half concrete fence, and the difference between the height of the upper half support beam and the height of the lower half concrete fence ranges from 100 mm to 200 mm to form an operation space for pouring, vibrating, finishing and roughening operations.

5. The tunneling roadway floor hardening mold of claim 1, wherein, The front and rear ends of the left and right fences are connected by a latch structure to realize the longitudinal extension of the mold. The mold also includes front and rear auxiliary gentle slopes; 6. A method for hardening a tunnel floor by using the tunnel floor hardening mold according to any one of claims 1 to 5, characterized by, The front and rear auxiliary gentle slopes are connected to the ends of the pedestrian walkways to realize the smooth transition of the pedestrian walkways to the roadway floor. Comprise: When the heading machine, self-moving tail or anchor rod trolley tail reaches a new fixed location, cleaning and leveling operations are performed on the preset hardening location; The one-stage tunnel heading floor hardening mold is disassembled and transported to the three-stage mold erection site; Road surface hardening operations, including pouring, vibrating, finishing and roughening, are performed in the three-stage mold; 7. The tunneling roadbed hardening method according to claim 6, characterized by, After the road surface hardening operations are completed, the pedestrian walkway is covered on the longitudinal rib support beams to restore the pedestrian walkway. The mold erection step specifically comprises: When the one-stage mold is initially erected, a ground anchor auxiliary mold erection is set up; 8. The tunneling roadway floor hardening method according to claim 6, characterized by, In subsequent mold erection, the previous stage concrete is used as the mold stable foundation. The step of disassembling the one-stage tunnel heading floor hardening mold also comprises: The two-stage pedestrian walkway is disassembled; 9. The tunneling roadway floor hardening method according to claim 6, characterized by, After the road surface hardening operations are completed, the disassembled two-stage pedestrian walkway is used for covering.

10. The tunneling roadway floor hardening method according to claim 6, characterized by, In the road surface hardening operations, the workers lay a longitudinal rib support beam after completing the pouring of a longitudinal rib distance of concrete foundation; after all the longitudinal rib support beams are laid and the entire hardening operations are completed, the pedestrian walkway is paved. The cleaning operation targets small-scale accumulated water, coal slurry and scattered residual coal powder.

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