Joining tunnel structure component applicable to tension and compression deformation and construction method

Abstract

The invention is suitable for the technical field of tunnel engineering, and provides a tunnel connecting structure component suitable for tension and compression deformation and a construction method. The tunnel joining structural component applicable to tension and compression deformation comprises a box-type structural component and cement-based foam concrete, the box-type structural component is arranged between the two tunnel plates and comprises a box-type structure and a plurality of corrugated alloy plates, the corrugated alloy plates are fixed between the two opposite inner walls of the box-type structure in parallel, the two ends of the box-type structure are fixed to the two tunnel plates, and the corrugated propagation direction of the corrugated alloy plates is consistent with the radial direction of the tunnel; the position between the two tunnel plates is filled with the cement-based foam concrete, and the position between the two tunnel plates is wrapped with the box-type structural component. And the outer surface of the cement-based foam concrete is coated with a waterproof layer. According to the embodiment of the invention, tension and compression deformation can be resisted, so that tunnel plates on the two sides are supported and protected, and the service life is long.

Description

Technical Field

[0001] This application relates to the field of tunnel engineering technology, specifically to a connecting tunnel structural component and construction method applicable to tensile and compressive deformation. Background Technology

[0002] As the core structure of underground transportation engineering, the structural safety of tunnels is particularly important when facing earthquakes, geological fault activity, or uneven ground settlement. Traditional tunnel connection structures mostly adopt rigid connections (such as continuous reinforced concrete lining) or simple expansion joint designs, but these have significant defects under dynamic tensile and compressive deformation. Therefore, continuously improving the overall stability and durability of tunnel structures has become a key task in the field of transportation construction.

[0003] One related technology provides an adaptive segmental flexible connection structure for tunnel lining. By arranging flexible connectors between two adjacent secondary lining segments, the joints of the secondary lining segments have greater stiffness, making them less prone to breakage under significant earthquake damage or large-scale energy impacts. This technology can enhance the mechanical properties of tunnel joints; however, the entire device is exposed to air, making the flexible connectors susceptible to oxidation and damage, potentially leading to the failure of the entire component.

[0004] Related technology 2 provides a steel truss protective structure for the connection between a bridge and a tunnel. A V-shaped protective cover plate is snapped into the groove of the support column, preventing debris from accumulating on the upper surface of the V-shaped cover plate and causing the structure to collapse due to overweight, thus improving the practicality of the equipment. This technology can effectively withstand externally applied vertical pressure, but the entire device cannot effectively resist external tensile and shear forces applied to the connection.

[0005] The inventors of this application have discovered through research that there is relatively little research on performance-enhancing components for tunnel joints. How to provide a deformable joint tunnel structure component that can efficiently resist tensile and compressive deformation and has a long service life is a technical problem that needs to be solved in this field. Summary of the Invention

[0006] In view of this, the present application provides a connecting tunnel structure component and construction method that is applicable to tensile and compressive deformation, which can resist tensile and compressive deformation and thus support the tunnel slabs on both sides, and has a long service life.

[0007] To achieve the above objectives, this application adopts the following technical solution:

[0008] In a first aspect, embodiments of this application provide a connecting tunnel structure component that is adaptable to tensile and compressive deformation, including a box-type structure component and cement-based foamed concrete;

[0009] The box-shaped structure component is disposed between two tunnel panels and includes a box-shaped structure and multiple corrugated alloy plates. The multiple corrugated alloy plates are fixed in parallel between two opposite inner walls of the box-shaped structure. The two ends of the box-shaped structure are fixed to the two tunnel panels. The two opposite inner walls are the side wall of the box-shaped structure near the outside of the tunnel panel and the side wall near the inside of the tunnel panel. The corrugation propagation direction of the corrugated alloy plates is consistent with the radial direction of the tunnel.

[0010] The cement-based foamed concrete is filled between the two tunnel slabs, and the box-shaped structural component is wrapped between the two tunnel slabs; wherein, the outer surface of the cement-based foamed concrete is coated with a waterproof layer.

[0011] Based on the first aspect, in some embodiments, a welded alloy plate is provided at the position corresponding to the tunnel panel and the box-shaped structure component. The welded alloy plate is fixed to the tunnel panel by bolts, and the two ends of the box-shaped structure are fixed to the welded alloy plate by welding.

[0012] Based on the first aspect, in some embodiments, the box-shaped structure includes four steel plates that form the box-shaped structure. The edges of two adjacent steel plates are respectively provided with protrusions and grooves. The two adjacent steel plates are connected by inserting the protrusions into the grooves and welding them. The box-shaped structure has two opposing openings.

[0013] Based on the first aspect, in some embodiments, the vertical distance between two adjacent vertices of the corrugated alloy plate is 20mm to 50mm, and the length of the corrugated alloy plate is 60mm to 150mm.

[0014] Based on the first aspect, in some embodiments, the thickness of the waterproof layer is 2 mm, and the waterproof layer is a polyurea waterproof coating, which includes an isocyanate component and an amino compound component, with a volume ratio of isocyanate component to amino compound component of 1:0.8 to 1:1.2.

[0015] Based on the first aspect, in some embodiments, there are multiple box-shaped structural components between the two tunnel sections, which are evenly distributed between the two tunnel sections, and the cement-based foamed concrete fills the space between the two tunnel sections, thus covering the space between the multiple box-shaped structural components.

[0016] Based on the first aspect, in some embodiments, the distance between the centers of two adjacent box-shaped structural components is L = 0.03D + 1.2, where D is the tunnel diameter, and both D and L are in meters.

[0017] Secondly, embodiments of this application provide a construction method for connecting tunnel structural components applicable to tensile and compressive deformation, the construction method comprising:

[0018] Welded alloy plates are installed at predetermined positions on the tunnel slabs;

[0019] Weld the two ends of the box-shaped structural component to the welding alloy plate;

[0020] Temporary formwork is erected between two adjacent tunnel slabs, so that the box-shaped structural components are located in the casting space enclosed by the temporary formwork and the two tunnel slabs;

[0021] Cement-based foamed concrete is poured into the pouring space in layers, so that the box-shaped structural components are completely covered by cement-based foamed concrete.

[0022] After the cement-based foamed concrete has initially set, remove the temporary formwork and set a curing time for the initially set cement-based foamed concrete.

[0023] A waterproof layer is sprayed onto the surface of cement-based foamed concrete.

[0024] Based on the second aspect, in some embodiments, cement-based foamed concrete is poured in multiple layers, each layer being ≤300mm thick, and a vibrating device is used to vibrate each layer of cement-based foamed concrete during layered pouring to remove air bubbles from the cement-based foamed concrete.

[0025] Based on the second aspect, in some embodiments, spraying a waterproof layer onto the surface of cement-based foamed concrete includes:

[0026] Polyurea waterproof coating was uniformly sprayed onto the surface of cement-based foamed concrete using a high-pressure airless spraying device. The polyurea waterproof coating was sprayed in three coats, with each coat having a thickness of 0.5mm to 0.7mm. The integrity of the polyurea waterproof coating was checked using an electric spark tester to ensure that the adhesion was ≥2.5MPa.

[0027] The advantages of the embodiments of this application compared to the prior art include:

[0028] In this embodiment, the box-shaped structural component can adapt to external forces through the tensile, compressive, and bending deformation of its thin walls, thereby continuing to function as a connector between tunnel sections even after being subjected to external forces. Furthermore, it fractures under strong external forces, thus protecting the overall tunnel structure. The cement-based foamed concrete is a high-density foamed concrete with excellent durability, strength, compressive properties, and elasticity. When subjected to small compressive deformation or tensile failure, it provides load-bearing capacity, ensuring structural load-bearing capacity, integrity, and prevents failure when small expansion and contraction occur at the joints. Under large compressive deformation or tensile failure, it ensures concrete fracture at the joints, absorbing and releasing energy and ensuring the predetermined damage location for the overall stability of the tunnel structure. A waterproof layer is applied to the surface of the cement-based foamed concrete, reducing its water absorption rate and extending its service life, thus enhancing its overall mechanical properties.

[0029] In addition, polyurea waterproof coating is selected for the waterproof layer. Polyurea waterproof coating has the property of resisting compressive and tensile forces, which can enhance the overall mechanical properties of cement-based foamed concrete. At the same time, because the polyurea waterproof coating has a large bonding strength with the surface of cement-based foamed concrete, it is not easy to fall off and fail.

[0030] This application can significantly improve the toughness and durability of vulnerable parts of tunnel joints, enhance the overall stability and bearing capacity of the tunnel structure, better withstand stress and adapt to deformation caused by tensile and compressive forces under external forces, ensure the ability to adapt to tunnel slip deformation, and reduce the impact of excessive stress or excessive inelastic deformation caused by external forces on tunnel joints and the overall tunnel structure. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 A three-dimensional structural schematic diagram of a connecting tunnel structural component suitable for tensile and compressive deformation, provided in an embodiment of this application;

[0033] Figure 2 for Figure 1 The main view;

[0034] Figure 3 for Figure 2 Top view;

[0035] Figure 4A schematic diagram showing a connecting tunnel structure component suitable for tensile and compressive deformation disposed between two tunnel sections, as provided in an embodiment of this application.

[0036] Figure 5 This is a schematic diagram showing the connection between the box-shaped structural component and the tunnel panel provided in an embodiment of this application;

[0037] Figure 6 A schematic diagram illustrating the arrangement of multiple connecting tunnel structural components adaptable to tensile and compressive deformation between two tunnel sections, as provided in an embodiment of this application;

[0038] Figure 7 for Figure 6 Top view;

[0039] Figure 8 This is a schematic flowchart illustrating the construction method for a connecting tunnel structural component that is subject to tensile and compressive deformation, as provided in the embodiments of this application. Detailed Implementation

[0040] The present application will be described more clearly below with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the function of the present application, but do not limit the present application in any way. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present application. These all fall within the protection scope of the present application.

[0041] To make the objectives, technical solutions, and advantages of this application clearer, the following description will be provided in conjunction with the accompanying drawings and specific embodiments.

[0042] See Figures 1 to 4 This application provides a connecting tunnel structure component that is adaptable to tensile and compressive deformation, including a box-type structure component 20 and cement-based foamed concrete 30.

[0043] A box-shaped structural component 20 is disposed between two tunnel slabs 10. The box-shaped structural component 20 includes a box-shaped structure 21 and multiple corrugated alloy plates 22. The multiple corrugated alloy plates 22 are fixed in parallel between two opposite inner walls of the box-shaped structure 21. The two ends of the box-shaped structure 21 are fixed to the two tunnel slabs. The two opposite inner walls are the sidewalls of the box-shaped structure 21 near the outside of the tunnel slabs and the sidewalls near the inside of the tunnel slabs. The corrugation direction of the corrugated alloy plates 22 is consistent with the radial direction of the tunnel.

[0044] Cement-based foamed concrete 30 is filled between the two tunnel slabs 10, and the box-shaped structural component 20 is wrapped between the two tunnel slabs 10. The outer surface of the cement-based foamed concrete 30 is coated with a waterproof layer 40.

[0045] In this embodiment, the box-shaped structural component 20 can adapt to external forces through the tensile, compressive, and bending deformation of its thin walls, thereby continuing to function as a connector between tunnel sections even after being subjected to external forces. Moreover, it will break apart under strong external forces, thus protecting the overall tunnel structure. The cement-based foamed concrete 30 is a high-density foamed concrete with good durability, strength, compressive properties, and elastic properties. When subjected to small compressive deformation or tensile failure, the cement-based foamed concrete can provide load-bearing capacity, ensuring the structural load-bearing capacity, integrity, and non-failure when small expansion and contraction deformation occurs at the joint. Under large compressive deformation or tensile failure, it ensures that the concrete at the joint breaks apart, achieving the purpose of absorbing and releasing energy and ensuring the predetermined damage location for the overall stability of the tunnel structure. Coating the surface of the cement-based foamed concrete 30 with a waterproof layer 40 can reduce the water absorption rate of the cement-based foamed concrete 30, extend its service life, and thus enhance the overall mechanical properties of the cement-based foamed concrete 30.

[0046] In some embodiments, see Figure 1 and Figure 5 Welded alloy plates 50 are provided at the positions corresponding to the tunnel section 10 and the box-shaped structure component 20. The welded alloy plates 50 can be fixed to the tunnel section 10 by bolts 51. The two ends of the box-shaped structure 21 are fixed to the welded alloy plates 50 by welding.

[0047] In some embodiments, the corrugated alloy plate 22 can be serrated, sinusoidal, or other similar corrugated shapes. This embodiment uses a serrated shape as an example. Figure 2 As shown, the vertical distance H between two adjacent vertices of the corrugated alloy plate 22 is 20mm to 50mm, and the length L of the corrugated alloy plate 22 (i.e., the distance between the two relative inner walls of the corrugated alloy plate fixed by the box structure 21) is 60mm to 150mm.

[0048] In this embodiment, the corrugated alloy plate 22 adopts a sinusoidal wave design with a wave height H of 20mm~50mm and a wavelength L of 60mm~150mm. The wave propagation direction is consistent with the radial direction of the tunnel, ensuring uniform stress distribution under cyclic loading. Simultaneously, the waveform of the corrugated alloy plate 22 allows it to adapt to ground deformation.

[0049] In some embodiments, auxiliary reinforcing components may be provided at fatigue-prone locations of the box-shaped structural component 20 for reinforcement. For example, fatigue-prone locations of the box-shaped structural component 20 may be the connection between the corrugated alloy plate 22 and the box-shaped structure 21, and the bending points of the corrugated alloy plate 22.

[0050] For example, the aforementioned auxiliary reinforcing component can be a high-strength, wear-resistant rubber gasket, such as an EPDM rubber gasket, which can be wrapped around the outside of the connection between the corrugated alloy plate 22 and the box-shaped structure 21.

[0051] For example, the aforementioned auxiliary reinforcing component can be a high-strength spring, which is disposed at the bend of the corrugated alloy plate 22, with the two ends of the spring connected to the alloy plates on both sides of the bend.

[0052] In this embodiment of the application, by adding auxiliary reinforcing components to the fatigue-prone locations of the box-shaped structural component 20, the tensile and compressive strength of the box-shaped structural component 20 and its elastic deformation resistance can be greatly improved, thereby increasing the service life of the box-shaped structural component 20.

[0053] In some embodiments, the box-shaped structure 21 may include four steel plates forming the shape of the box-shaped structure 21. The edges of adjacent steel plates are respectively provided with protrusions and grooves. Adjacent steel plates are connected by inserting the protrusions into the grooves and welding them together. The box-shaped structure 21 has two opposing openings, such as... Figure 1 As shown, Figure 1 Only one opening is shown in the middle, the other opening is... Figure 1 The openings shown are opposite each other. The two opposite openings of the box-shaped structure 21 are welded to the welded alloy plate 50.

[0054] For example, the box-type structural component 20 can be made of carbon steel (e.g., Q235, Q345) and low alloy steel (e.g., Q355), with each steel plate having a thickness of approximately 6 mm.

[0055] In this embodiment, the cement-based foamed concrete 30 can be a cement-based foamed concrete with a density greater than 1000 kg / m³, a compressive strength of approximately 3 MPa, a flexural strength of approximately 0.6 MPa, and an elastic modulus of 10. 3 MPa~10 4 MPa. Cement-based foamed concrete provides load-bearing capacity under small compressive deformation or tensile failure, ensuring the structural load-bearing capacity, integrity, and prevents failure under small expansion and contraction at joints; under large compressive deformation or tensile failure, it ensures that the concrete at the joints fractures, absorbing and releasing energy, and pre-defined failure locations to ensure the overall structural stability of the tunnel. For a more detailed description of the density, compressive strength, and modulus of elasticity of cement-based foamed concrete, please refer to the relevant descriptions in the subsequent construction methods.

[0056] In some embodiments, the waterproof layer 40 can be a polyurea waterproof coating, which includes an isocyanate component and an amino compound component, and the volume ratio of the isocyanate component to the amino compound component can be 1:0.8 to 1:1.2.

[0057] Polyurea waterproof coatings can form a seamless waterproof layer with high elasticity, tensile strength, and compressive strength, effectively preventing moisture penetration and protecting tunnel structures. Furthermore, polyurea waterproof coatings possess compressive and tensile strength resistance, thus enhancing the overall mechanical properties of cement-based foamed concrete 30. Simultaneously, the bonding strength between the polyurea waterproof coating and the surface of cement-based foamed concrete 30 is high, making it less prone to detachment and failure.

[0058] For example, the above-mentioned polyurea waterproof coating should have the following properties: tensile strength greater than or equal to 10 MPa, elongation at break greater than or equal to 300%, stable performance in the temperature range of -40°C to 120°C, bonding strength with cement-based foamed concrete surface greater than or equal to 2.5 MPa, and resistance to acids, alkalis, salts and various chemical media.

[0059] In this embodiment, the thickness of the waterproof layer 40 can be 2 mm.

[0060] See Figure 6 and Figure 7 There can be multiple box-shaped structural components 20 between the two tunnel slabs 10. These multiple box-shaped structural components 20 are evenly distributed between the two tunnel slabs 10. Cement-based foamed concrete 30 is filled between the two tunnel slabs 10, and the multiple box-shaped structural components 20 are covered between the two tunnel slabs 10.

[0061] The distance between the centers of two adjacent box-shaped structural components 20 is L = 0.03D + 1.2, where D is the tunnel diameter, and both D and L are in meters.

[0062] The formula L = 0.03D + 1.2 will be explained below.

[0063] Based on the load distribution model of the tunnel's circumferential support (such as the analysis of a simply supported beam or continuous beam under uniform load), the relationship between the interval and the diameter is derived by using the stress formula σ=WM. Assuming the allowable stress of the titanium alloy is σ, and the load intensity is proportional to the tunnel diameter D (e.g., the surrounding rock pressure increases with increasing diameter), L∝D can be obtained by balancing the bending moment M∝D⋅L² and the section modulus W. However, the formula shows a linear relationship L∝D, which may be simplified to an engineering approximation or empirical fitting. The high strength characteristics of titanium alloy (elastic modulus E≈110GPa, yield strength σy≈800MPa) allow for a larger interval, but this needs to be adjusted in conjunction with a safety factor (e.g., 1.5~2.0). Finally, the proportionality coefficient is determined to be 0.03 through experiments or numerical simulations (e.g., finite element analysis).

[0064] The installation spacing of conventional equipment in tunnels (such as ventilation ducts and cable supports, which are typically no less than 1.0 to 1.5 meters) is referenced, and the structural dimensions of the box-type structural component 20 (such as the length and width of the box-type structure 21) are considered. By fitting support interval data from field tests or existing engineering cases (such as a subway tunnel or a mountain tunnel), and after removing outliers, an intercept term of 1.2 meters is obtained, which serves as a universally applicable basic parameter. Therefore, L = 0.03D + 1.2 is obtained.

[0065] In this embodiment of the application, three, four, or more box-shaped structural components may be provided between two tunnel sections, and the specific number of box-shaped structural components is not limited.

[0066] In this embodiment, the cross-section of the tunnel body can be circular, horseshoe-shaped, or other shapes, and is not limited thereto.

[0067] The working principle of the connecting tunnel structural components that can be subjected to tensile and compressive deformation is explained below.

[0068] 1. Energy dissipation due to elastic deformation of corrugated alloy plates

[0069] The corrugated alloy plate adopts a sinusoidal wave design with a wave height H of 20mm~50mm and a wavelength L of 60mm~150mm. The wave propagation direction is consistent with the radial direction of the tunnel, ensuring uniform stress distribution under cyclic loading. At the same time, the waveform allows the structure to adapt to ground deformation.

[0070] The corrugated alloy plate is made of Q355B low alloy steel, and the material can withstand ≥2×10 within a strain range of ±3%. 4 The fatigue life of the double-cycle load is more than 3 times that of the flat steel plate.

[0071] Tension stage: The corrugated alloy plate is stretched radially, and the spacing between the corrugations increases. The tensile stress is offset by the storage of elastic potential energy, and the elastic strain energy density is ≥15kJ / m³.

[0072] Compression stage: When the stress exceeds the yield strength (355MPa), the corrugated alloy plate enters the plastic buckling stage, dissipating energy through local deformation, with plastic energy dissipation accounting for ≥60%;

[0073] Collaborative operation: Absorbs seismic energy through controlled plastic deformation to protect the main structure.

[0074] 2. Rigid support and coordinated deformation of box-type structures

[0075] The enclosure is a closed structure formed by welding four 6mm thick Q235B steel plates together using a raised-groove method. The shear strength of the weld joint between adjacent steel plates is ≥120MPa. The in-plane bending stiffness EI of the enclosure is ≥1.2×10⁻⁶. 6N·m², which can effectively suppress circumferential deformation of the tunnel.

[0076] The two ends of the enclosure are connected to the tunnel slabs by a hybrid bolted and welded connection using 10mm thick Q345B alloy plates, with the bolt torque controlled within the range of 180~220 N·m. This connection method forms a rigid force transmission chain, with a measured tensile and compressive load transmission efficiency of ≥90% and a shear stress reduction of ≈40%, which is significantly better than the traditional single connection method.

[0077] The box-type structure improves the stability of the columns through internal stiffening ribs, preventing brittle failure under earthquake loads.

[0078] The following explains the protective effect of connecting tunnel structural components that can withstand tensile and compressive deformation on the tunnel.

[0079] 1. Resisting tensile and compressive deformation

[0080] The box-type structure achieves graded adaptation to tensile and compressive deformation through a triple mechanism of "rigid frame, corrugated energy dissipation, and interface reinforcement":

[0081] Elastic phase: Corrugated alloy plate deformation and rigid box support maintain structural integrity;

[0082] Plastic stage: buckling energy dissipation of corrugated alloy plates and controlled fragmentation of concrete absorbs impact energy;

[0083] Failure control: The formula for the spacing between the boxes ensures that damage is localized, protecting the safety of the main tunnel.

[0084] 2. Enhance overall stability

[0085] Multiple sets of box-shaped structural components are evenly distributed at intervals L, forming a continuous circumferential support system, which improves the bending stiffness and shear resistance of the tunnel structure, especially in fault zones or soft rock formations.

[0086] 3. Collaborative material protection

[0087] Cement-based foamed concrete (density > 1000 kg / m³, compressive strength ≥ 10 MPa) is used to encapsulate box-shaped structural components. The porous structure of cement-based foamed concrete provides a buffering effect and further disperses stress. At the same time, the high elastic modulus (5 GPa ~ 20 GPa) of cement-based foamed concrete ensures deformation coordination and avoids debonding between cement-based foamed concrete components.

[0088] Polyurea waterproof coatings isolate moisture and chemical erosion, protecting box-type structural components and cement-based foamed concrete from corrosion and extending their service life.

[0089] 4. Adapt to dynamic environments

[0090] Under temperature changes or cyclic loads (such as train vibration), the box-type structural components absorb some of the impact energy through the elastic deformation of the corrugated alloy plates. The rigid supports of the box-type structure and the internal corrugated alloy plates work together to maintain structural integrity and prevent fatigue failure. The box-type structural components and cement-based foamed concrete also work together to resist damage under seismic loads, significantly protecting the main tunnel structure.

[0091] The aforementioned tunnel structural components suitable for tensile and compressive deformation include box-type structural components that can adapt to external forces through the tensile, compressive, and bending deformation of their thin walls. This allows them to continue functioning as connecting tunnel sections even after being subjected to external forces, and they will fracture under stronger external forces, thus protecting the overall tunnel structure. Cement-based foamed concrete is a high-density foamed concrete with good durability, strength, compressive properties, and elasticity. When subjected to small compressive deformation or tensile failure, cement-based foamed concrete can provide load-bearing capacity, ensuring the structural load-bearing capacity, integrity, and non-failure under small expansion and contraction deformation at the joints. Under large compressive deformation or tensile failure, it ensures that the concrete at the joints fractures, absorbing and releasing energy and ensuring the predetermined damage location for the overall stability of the tunnel structure. A waterproof layer is applied to the surface of the cement-based foamed concrete, which reduces its water absorption rate, extends its service life, and thus enhances its overall mechanical properties.

[0092] In addition, polyurea waterproof coating is selected for the waterproof layer. Polyurea waterproof coating has the properties of resistance to compressive and tensile forces, which can enhance the overall mechanical properties of cement-based foamed concrete. Moreover, the polyurea waterproof coating has a large bonding strength with the surface of cement-based foamed concrete, making it less prone to detachment and failure. The box-type structure made of carbon steel and low alloy steel has high strength, high reliability and excellent fatigue performance. Adding auxiliary reinforcing components to the fatigue-prone parts of the box-type structure can greatly improve the tensile and compressive strength of the box-type structure components, as well as the effect of elastic deformation and service life.

[0093] This application can significantly improve the toughness and durability of vulnerable parts of tunnel joints, enhance the overall stability and bearing capacity of the tunnel structure, better withstand stress and adapt to deformation caused by tensile and compressive forces under external forces, ensure the ability to adapt to tunnel slip deformation, and reduce the impact of excessive stress or excessive inelastic deformation caused by external forces on tunnel joints and the overall tunnel structure.

[0094] See Figure 8 The construction method for connecting tunnel structural components applicable to tensile and compressive deformation provided in this application embodiment may include steps 801 to 806, as detailed below:

[0095] Step 801: Install welding alloy plates at preset positions on the tunnel panels.

[0096] The hinged base can be made of steel plate and may have bolt holes. Bolts are used to secure the hinged base firmly to the tunnel slab. For example, a torque wrench can be used to tighten the bolts to a torque value of 180 N·m to 220 N·m. The torque value indirectly reflects the axial preload of the bolts. The setting range of 180 N·m to 220 N·m ensures that the preload of all bolts is evenly distributed, avoiding local overload or insufficient preload.

[0097] Step 802: Weld the two ends of the box-shaped structural component to the welding alloy plate.

[0098] For example, multiple box-shaped structural components are evenly spaced between two adjacent tunnel sections, and the distance between the centers of two adjacent box-shaped structural components is L = 0.03D + 1.2, where D is the tunnel diameter and both D and L are in meters.

[0099] After calculating the distance L between the centers of two adjacent box-shaped structural components using L=0.03D+1.2, the position of the center of each box-shaped structural component can be determined. Combined with the dimensions of the box-shaped structure, the positions of its two ends can then be determined. For example, if a certain position of the tunnel slab is set as the center of the first box-shaped structural component, then the positions of the centers of all other box-shaped structural components can be determined using L=0.03D+1.2. If the box-shaped structure is in... Figure 5 The vertical length shown is 2x. Then, the center position of the box structure is extended to both sides by a distance x, which is the position of the two ends of the box structure on the tunnel slab.

[0100] For example, an alloy steel (Q355) box-type structure can be prefabricated according to design requirements. The wall thickness of the box-type structure is 6mm. Then, multiple corrugated alloy plates are welded to two opposite inner walls of the box-type structure. Surface cracks in the concealed welds inside the box-type structure are detected using magnetic particle testing.

[0101] For example, prefabricated box-type structural components can be hoisted to the connection point and fixed to the welded alloy plates on the tunnel slab by welding. Temporary support frames are then used to ensure accurate structural positioning and prevent installation deformation. Afterward, the weld quality is inspected using ultrasonic or X-ray testing to ensure that the weld fusion area is ≥90%.

[0102] Step 803: A temporary template is erected between two adjacent tunnel slabs so that the box-shaped structural component is located in the casting space enclosed by the temporary template and the two tunnel slabs.

[0103] Cement-based foamed concrete will shrink to a certain extent during the solidification process. In order to compensate for the effect of shrinkage, a 3‰ pre-camber can be set on the temporary formwork. In this way, after the cement-based foamed concrete solidifies and shrinks, the surface of the cement-based foamed concrete will be relatively flat and will not be sunken.

[0104] Cement-based materials undergo drying shrinkage and chemical shrinkage during solidification due to moisture evaporation and hydration reactions of cementitious materials. Foamed concrete, due to its porous structure, may have a slightly higher shrinkage rate than ordinary concrete, but experimental tests (such as linear shrinkage tests under standard curing conditions) show that its average linear shrinkage rate is approximately 0.3% (3‰). Setting the pre-camber to the same proportion as the shrinkage rate (3‰) essentially counteracts the depressions caused by shrinkage through "reverse pre-deformation," resulting in a smooth final surface.

[0105] Step 804: Cement-based foamed concrete is poured in layers into the pouring space so that the box-shaped structural components are completely covered by cement-based foamed concrete.

[0106] The cement-based foamed concrete can be poured in multiple layers (e.g., 3 layers), with each layer having a thickness of ≤300 mm. During the layered pouring, a vibrating device is used to vibrate each layer of cement-based foamed concrete to remove air bubbles from the cement-based foamed concrete.

[0107] The effective range of vibratory compaction equipment is limited (typically, the effective depth of a vibrator is about 300-500mm). A layer thickness of ≤300mm ensures that the vibration force is evenly distributed throughout the entire pour, preventing air bubbles from being trapped in the lower layers due to excessively thick pours. If a single pour is too thick, the lower layers of concrete may form an "air bubble trap" due to insufficient vibration force, leading to localized looseness and uneven strength. Layered pouring ensures that each layer of concrete is within the optimal effective range of the vibratory compaction equipment, guaranteeing sufficient air bubble removal and improving material density and integrity.

[0108] Step 805: After the cement-based foamed concrete has initially set, remove the temporary formwork and set a preset curing time for the initially set cement-based foamed concrete.

[0109] For example, after the cement-based foamed concrete has initially set, the temporary formwork is removed, and then a moisturizing film is placed on top of the cement-based foamed concrete. It is then cured for 14 days in a constant temperature and humidity environment of 20±2℃ and ≥95%. After the cement-based foamed concrete has cured, the surface dust is removed, and the concrete is dried.

[0110] In this step, the solidified cement-based foamed concrete has a density >1000 kg / m³, a compressive strength of approximately 5 MPa, a flexural strength of approximately 0.6 MPa, freeze-thaw resistance (≥25 freeze-thaw cycles, mass loss ≤5%), water absorption ≤10%, and an elastic modulus of 10. 3MPa~10 4 MPa.

[0111] The density of cement-based foamed concrete is mainly determined by the proportions of cementitious materials (cement, admixtures), aggregates (sand, mineral fillers), and foam. A density >1000 kg / m³ indicates a high proportion of solid components (cement stone, aggregates) and moderate porosity in the material. This ensures both lightweight characteristics (compared to 2400 kg / m³ for ordinary concrete) and meets the basic requirements for material density in structural load-bearing or engineering applications (e.g., walls, floor subbases, etc., need to have certain compressive strength and durability).

[0112] 10 MPa is a commonly used strength threshold for structural or semi-structural materials (e.g., masonry blocks and non-load-bearing walls in low-rise buildings require ≥5 MPa, while load-bearing walls require ≥15 MPa). This strength requirement ensures that the material does not fail when subjected to its own weight, construction loads, or minor external loads, while also meeting relevant standards (e.g., the strength requirements for different density grades in GB / T 29062-2012 "Foamed Concrete").

[0113] The elastic modulus reflects a material's ability to resist elastic deformation and is directly related to density, porosity, and aggregate stiffness. The elastic modulus of ordinary concrete is approximately 20 GPa-40 GPa, while that of foamed concrete, which contains air pores, is typically lower (approximately 5 GPa-20 GPa).

[0114] By rationally designing the mix proportion (increasing cementitious materials and aggregates, controlling the amount of foam), optimizing the production process (uniform mixing, curing conditions), and controlling the microstructure (porosity, crystal morphology), cement-based foamed concrete can simultaneously meet the above requirements for density, strength, and modulus of elasticity.

[0115] Step 806: Spray a waterproof layer onto the surface of the cement-based foamed concrete.

[0116] For example, a high-pressure airless spraying device can be used to uniformly spray polyurea waterproof coating onto the surface of cement-based foamed concrete. The polyurea waterproof coating is sprayed in three coats, with each coat having a thickness of 0.5mm to 0.7mm. An electric spark tester is used to check the integrity of the polyurea waterproof coating to ensure that the adhesion is ≥2.5MPa.

[0117] In addition, after the polyurea waterproof coating has cured, it is necessary to test the bonding strength, tensile strength and elongation at break of the polyurea waterproof coating. The bonding strength should be ≥2.5MPa, the tensile strength should be ≥10MPa (e.g., 16MPa), the elongation at break should be ≥300% (e.g., 450%), the weather resistance should be -40℃ to 120℃, and the strength retention rate after 1500 hours of accelerated aging test under artificial climate should be ≥80%. If there are any areas that do not meet the standards, those areas should be repaired and recoated.

[0118] Polyurea waterproof coatings are commonly used on various building surfaces, such as roofs, bridges, and pools, and require a strong bond to the substrate. A bond strength of ≥2.5MPa ensures that the coating will not easily detach from the substrate during long-term use, even under the influence of external factors such as temperature changes, vibration, and water pressure, thus guaranteeing the integrity and effectiveness of the waterproofing system.

[0119] The requirement of tensile strength ≥10MPa is to ensure that the polyurea waterproof coating can withstand a certain amount of external tensile force without damage. In actual use, the coating may be subjected to tensile forces due to slight deformation of the building, thermal expansion and contraction, etc. Sufficient tensile strength can ensure that the coating maintains stable performance under these conditions, prevents cracks or breaks, and maintains good waterproof effect.

[0120] The requirement of an elongation at break of ≥300% is because buildings inevitably undergo some minor deformations during use. Polyurea waterproof coatings have a high elongation at break, which allows them to adapt to these deformations, expanding and contracting with the substrate without cracking due to minor substrate deformation, thus preventing loss of waterproofing function.

[0121] The achievement of the above-mentioned properties of polyurea waterproof coatings in terms of bond strength, tensile strength, and elongation at break is crucial to the preparation of the substrate surface (i.e., the surface of cement-based foamed concrete). The substrate must be clean, dry, and free of oil, dust, and loose materials; otherwise, the bond strength between the coating and the substrate will be affected. For example, if the substrate is oily, the polyurea waterproof coating will not be able to make close contact with the substrate, resulting in poor adhesion and failure to meet the required bond strength.

[0122] The performance of polyurea waterproof coatings is affected by parameters such as temperature, humidity, pressure, and spray gun movement speed. Low temperatures may lead to incomplete curing, affecting tensile strength and elongation at break. High humidity can cause bubbles or pinholes to form on the coating surface, reducing its density and consequently impacting its properties. Appropriate spray pressure and spray gun movement speed ensure uniform coating thickness, preventing areas of excessive thickness or thinness. Uneven thickness leads to uneven stress distribution, affecting tensile strength and elongation at break.

[0123] The thickness of polyurea waterproof coating should meet the design requirements. A coating that is too thin cannot provide sufficient material properties to meet the requirements of various indicators. For example, tensile strength and elongation at break may not meet the standards due to insufficient material. On the other hand, a coating that is too thick not only wastes material, but may also lead to incomplete curing, affecting the bonding strength and other properties.

[0124] The main film-forming substance in polyurea waterproof coatings is resin. Adding appropriate amounts of fillers, such as calcium carbonate and talc, can improve the coating's workability and reduce costs, while also increasing the coating's hardness and tensile strength to some extent. However, the particle size, shape, and surface properties of the fillers can affect their dispersibility in the coating and their bonding with the resin. If the fillers are not dispersed evenly, they will become weak points in the coating, reducing its performance.

[0125] In some embodiments, the construction method for the above-mentioned connecting tunnel structural components applicable to tensile and compressive deformation may further include: cleaning the connecting surfaces of two adjacent tunnel slabs to ensure that the connecting surfaces are flat and free of debris; and sandblasting the connecting surfaces to make the surface roughness Ra≥50μm.

[0126] When subsequent sealing material filling or other connection treatments are performed, a roughness Ra≥50μm provides a larger surface area, allowing the sealing or connecting material to better interlock and bond with the joint surface. This ensures the sealing and firmness of the connection, effectively preventing leakage, deformation, and other problems during tunnel use. Appropriate roughness can increase the coefficient of friction between two joint surfaces, better resisting relative sliding when the tunnel is subjected to external forces such as earthquakes or ground movement, thus improving the stability and safety of the tunnel structure.

[0127] If the roughness is less than 50μm, the joint surface is relatively smooth, and the adhesion between the adhesive material and the joint surface may be insufficient. During long-term use, the sealant may fall off or fail, leading to gaps at the tunnel joint and affecting the tunnel's waterproof performance and structural stability. A smooth joint surface is also not conducive to forming an effective seal, making it easy for water, air, and other media to enter the tunnel through the gaps, causing corrosion and damage to the facilities inside the tunnel, and also affecting the tunnel's functionality and safety.

[0128] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. 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. Such 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, and should all be included within the protection scope of the present invention.

Claims

1. A tunnel structure component which is adaptable to tensile and compressive deformation, characterized by, The box structure component comprises a box structure and a plurality of corrugated alloy plates fixed between opposite inner walls of the box structure in parallel, the opposite inner walls are side walls close to the outside of the tunnel slab and side walls close to the inside of the tunnel slab, and the corrugated alloy plates are fixed on the side walls close to the outside of the tunnel slab. The box structure component comprises a box structure and a plurality of corrugated alloy plates fixed between opposite inner walls of the box structure in parallel, the opposite inner walls are side walls close to the outside of the tunnel slab and side walls close to the inside of the tunnel slab, and the corrugated alloy plates are fixed on the side walls close to the outside of the tunnel slab. The box structure comprises four steel plates, the four steel plates surround the box structure, edges of adjacent two steel plates are respectively provided with protrusions and grooves, the adjacent two steel plates are connected by inserting the protrusions into the grooves and welding, and the box structure has two opposite openings.

2. The stretchable and compressible interface tunnel structure component of claim 1, wherein, The vertical distance between adjacent two vertexes of the corrugated alloy plate is 20-50 mm, and the length of the corrugated alloy plate is 60-150 mm.

3. The stretchable and compressible interface tunnel structure component of claim 1, wherein, The thickness of the waterproof layer is 2 mm, the waterproof layer is polyurea waterproof paint, the polyurea waterproof paint comprises an isocyanate component and an amino compound component, and the volume ratio of the isocyanate component to the amino compound component is 1:0.8-1:1.

2.

4. The stretchable and compressible tunnel structure component of claim 1, wherein, The box structure component comprises a box structure and a plurality of corrugated alloy plates fixed between opposite inner walls of the box structure in parallel, the opposite inner walls are side walls close to the outside of the tunnel slab and side walls close to the inside of the tunnel slab, and the corrugated alloy plates are fixed on the side walls close to the outside of the tunnel slab.

5. The stretchable and compressible interface tunnel structural component of claim 1, wherein, The distance L between centers of adjacent two box structure components is 0.03D+1.2, D is the diameter of the tunnel, and the units of D and L are meters.

6. The stretchable and compressible interface tunnel structural component of claim 1, wherein, The construction method comprises:

7. The stretchable and compressible interface tunnel structure component of claim 6, wherein, The welding alloy plate is arranged at a preset position of the tunnel slab; 8. A construction method of a jointed tunnel structure member adaptable to tensile and compressive deformation, characterized by, The two ends of the box structure component are welded with the welding alloy plate; The temporary formwork is erected between the adjacent two tunnel slabs, so that the box structure component is located in the pouring space surrounded by the temporary formwork and the two tunnel slabs; The cement-based foam concrete is poured into the pouring space in layers, so that the box structure component is completely covered by the cement-based foam concrete; After the cement-based foam concrete is initially cured, the temporary formwork is removed, and the initially cured cement-based foam concrete is cured for a preset time; The surface of the cement-based foam concrete is sprayed with the waterproof layer. The cement-based foam concrete is poured in multiple layers, each layer has a thickness of ≤300 mm, and the cement-based foam concrete is vibrated by using a vibrating device during the layering pouring to remove air bubbles in the cement-based foam concrete. The surface of the cement-based foam concrete is sprayed with the waterproof layer, comprising:

9. The construction method of the applicable tensile and compressive deformation of the tunnel structure component of the link according to claim 8, characterized in that, ​ 10. The construction method of the applicable tension-compression deformation of the joint tunnel structure component according to claim 8, characterized in that, ​ The polyurea waterproof coating is uniformly sprayed on the surface of the cement-based foam concrete by using a high-pressure airless spraying device, the polyurea waterproof coating is sprayed for three times, the thickness of the polyurea waterproof coating is 0.5mm~0.7mm each time, and the integrity of the polyurea waterproof coating is checked by using an electric spark detector, so that the adhesion is greater than or equal to 2.5MPa.

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