Rapid construction method for old tunnel lining local replacement and steel corrugated plate composite reinforcement

Abstract

The invention provides a rapid construction method for old tunnel lining local replacement and steel corrugated plate composite reinforcement, and relates to the technical field of tunnel and underground engineering reinforcement and transformation construction. According to the construction method, the process interval is reduced by adopting the processes of sectional warehouse jumping and pre-nail planting, and the construction period is greatly shortened through assembly construction; the damage to the reserved structure is reduced through low-vibration cutting; the combination quality of a new structure and an old structure and the integrity of a composite structure are ensured through accurate positioning and dense pouring; the core material is a geopolymer, so that the cement consumption is reduced; and noise and dust pollution in the construction process is small.

Description

Technical Field

[0001] This invention relates to the field of tunnel and underground engineering reinforcement and renovation construction technology, and more specifically, to a rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates. Background Technology

[0002] For old tunnel linings with severe localized defects, traditional reinforcement methods such as full-line arching or shotcrete re-layout are characterized by large project volume, high carbon emissions, and long construction periods. When using partial removal and replacement, ensuring the quality of the bond between the old and new concrete, and efficiently and accurately installing corrugated steel plates to ensure they share the load with the lining are challenging aspects of construction. Therefore, we propose an improved, rapid construction method that combines partial replacement of old tunnel linings with composite reinforcement using corrugated steel plates. Summary of the Invention

[0003] This invention provides a rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates, comprising the following sequential steps: S1. Precise positioning and marking: collect point cloud data of the tunnel reinforcement section, identify the diseased area after processing, construct a BIM model and determine the cutting boundary and anchor layout, and perform digital verification after on-site layout; based on the tunnel inspection results, accurately mark the boundary of the concrete area to be cut on the lining surface, and mark the drilling position of the steel corrugated plate anchor at the same time. S2. Segmented skip-concrete removal: Low-vibration equipment is used to cut the damaged concrete along the boundary of the area to be removed. S3. Interface treatment and rebar installation: roughen and clean the old concrete interface exposed after removal to expose a solid base layer. Remove rust from the exposed rebar in the original lining and weld or tie new reinforcing rebars using rebar installation technology to form a rebar skeleton that combines the old and new. S4. Anchor nails are pre-installed. Drill holes at the marked locations of the corrugated steel plate anchor nails. After cleaning the holes, use a chemical anchoring agent to pre-install the anchor nails into the stable part of the original tunnel lining. S5. Positioning and assembly of corrugated steel plates: The prefabricated arc-shaped corrugated steel plates are hoisted to the predetermined position, and the reserved holes on them are passed through the ends of the pre-installed anchors. High-strength bolts are used to assemble and connect adjacent plates from the tunnel arch waist to the arch top to form a complete annular lining. S6. Filling and Vibration: Grouting holes and venting holes are pre-set on the top of the corrugated steel plate. The pre-prepared filler is injected into the cavity formed by the corrugated steel plate and the old lining surface through the bottom grouting hole using a pumping device. At the same time, an attached vibrator is used to vibrate the outer wall of the corrugated steel plate, or an insert vibrator is inserted through the reserved hole. S7. Curing and final anchoring: Water-retaining curing is carried out on the grouted filler area, and the nuts at all anchor ends are finally tightened to connect the steel corrugated plate, the geopolymer filling layer and the original lining into a whole.

[0004] As a preferred technical solution of this application, step S1 specifically includes: a. 3D laser scanning and data acquisition: A 3D laser scanner is used to perform a full-section scan of the tunnel reinforcement section to acquire point cloud data; b. Point cloud data processing and disease identification: Import point cloud data into processing software and automatically identify diseases by comparing the design model with the measured data; c. BIM model construction and surgical resection boundary determination: Establish a BIM model of the reinforced section, and determine the resection boundary based on the disease identification results using the "minimum resection principle"; d. Arrange anchors in a quincunx pattern in the BIM model: circumferential spacing of 500-1000mm and longitudinal spacing of 500-1000mm, avoiding the original lining main reinforcement positions, ensuring that the anchor embedment depth is ≥100mm, accurately lay out on site, and use a total station to project the boundary lines and anchor positions in the BIM model onto the lining surface. e. Use different colored ink lines to distinguish them; f. Digital verification: Use a portable scanner to verify the layout results. Deviation control: Positioning error ≤ 5mm, and generate a "Precise Positioning Acceptance Report".

[0005] As a preferred technical solution of this application, the defects include: lining deformation exceeding the limit (deformation > 50 mm), crack distribution network (width > 0.3 mm), and concrete spalling area (depth > 30 mm).

[0006] As a preferred technical solution in this application, the density of the point cloud data obtained in step a is ≥500 points / m². 2 The accuracy requirement is ±2mm.

[0007] As a preferred technical solution of this application, the "minimum excision principle" in step c includes: the boundary should extend at least 100mm beyond the outer edge of the diseased area, the boundary line should be a regular geometric shape (rectangle, trapezoid), the distance between adjacent excision areas should be ≥500mm, and the anchor placement should be digitally designed.

[0008] As a preferred technical solution of this application, in step e, when different colored ink lines are used to distinguish the concrete cutting boundary line, the blue line represents the center position of the anchor nail, and the green line represents the quality control checkpoint.

[0009] As a preferred technical solution of this application, the low-vibration equipment used in S2 includes a hydraulic chainsaw, a wire saw, or a silent crusher.

[0010] As a preferred technical solution of this application, when cutting the defective concrete in S2, the cutting is carried out in the order of "segmentation and skipping sections", that is, only a limited section of concrete is cut off at a time. After the cut section is backfilled and reinforced, the construction of the adjacent section is carried out to ensure the overall stability of the tunnel structure.

[0011] As a preferred technical solution of this application, the filler in S6 is fly ash-steel slag geopolymer mortar or concrete.

[0012] As a preferred technical solution of this application, the final tightening of the nuts at all anchor ends in S7 is carried out after the strength of the geopolymer filler reaches more than 75% of the design value.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: In the scheme of this application: 1. Highly efficient and rapid construction: The "segmented skip-section" and "pre-installed nails" processes reduce the intervals between procedures, and the modular construction significantly shortens the construction period; 2. Controllable quality and high reliability: Low-vibration cutting reduces damage to the preserved structure; precise positioning and dense grouting ensure the quality of the combination of new and old structures and the integrity of the composite structure; 3. Green and low-carbon: The core material is geopolymer, which reduces cement consumption; the construction process produces less noise and dust pollution; 4. High safety: The skip-construction method and rapid formation of the corrugated steel plate support system effectively control the structural risks of the tunnel during construction. Attached Figure Description

[0014] Figure 1 A flowchart illustrating the rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates provided in this application. Figure 2 This is a schematic diagram of the segmented pleural resection provided in this application; Figure 3 This is a schematic diagram of the assembly and pouring of the corrugated steel sheet provided in this application. Detailed Implementation

[0015] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0016] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the present invention can be combined with each other.

[0017] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0018] Example 1, please refer to Figures 1-3 It includes the following sequential steps: S1. Precise Positioning and Marking: This step is crucial for ensuring the accuracy of subsequent construction. Point cloud data of the tunnel reinforcement section is collected, processed, and the affected areas are identified. A BIM model is constructed, and the resection boundaries and anchor placement are determined. Digital verification is performed after on-site layout. Based on the tunnel inspection results, the boundaries of the concrete areas to be resected are precisely marked on the lining surface, and the drilling positions of the corrugated steel plate anchors are also marked. Precise identification of affected areas is achieved through point cloud data acquisition and BIM modeling, avoiding the subjective errors of traditional manual inspection. S2. Segmented skip-concrete removal: Low-vibration equipment is used to cut the damaged concrete along the boundary of the area to be removed. Low-vibration equipment can avoid the damage to the original intact lining area caused by the violent vibration of traditional crushing equipment, and prevent vibration from causing new cracks or deformation. S3. Interface treatment and rebar installation: The exposed old concrete interface after removal is roughened and cleaned to expose a solid base layer. The exposed rebar in the original lining is derusted, and new reinforcing bars are welded or tied using rebar installation technology to form a rebar skeleton that combines the old and new layers. Roughening and cleaning can remove laitance and loose layers from the old concrete interface, increasing the contact area between the old and new concrete, so that the subsequent filler can be tightly bonded to the old concrete. Derusting the rebar can restore the mechanical properties of the original rebar and prevent corrosion from affecting the structural bearing capacity. S4. Anchor nails are pre-installed. Drill holes at the marked locations of the corrugated steel plate anchor nails. After cleaning the holes, use a chemical anchoring agent to pre-install the anchor nails into the stable part of the original tunnel lining. S5. Positioning and assembly of corrugated steel plates: The prefabricated arc-shaped corrugated steel plates are hoisted to the predetermined position, with the reserved holes on them passing through the ends of the pre-installed anchors. High-strength bolts are used to assemble and connect adjacent plates from the tunnel arch waist to the arch crown, forming a complete annular lining. The prefabricated arc-shaped corrugated steel plates have high precision, and with the pre-installed anchors, accurate positioning can be achieved quickly, reducing on-site processing errors. The cooperation between the reserved holes and the anchors further ensures positioning accuracy. S6. Filler Injection and Vibration: Grouting holes and venting holes are pre-set on the top of the corrugated steel plate. The pre-prepared filler is injected into the cavity formed by the corrugated steel plate and the old lining surface through the bottom grouting holes using a pumping device. Simultaneously, an attached vibrator is used to vibrate the outer wall of the corrugated steel plate, or an inserted vibrator is inserted through the pre-drilled holes to ensure the polymer filler is dense and free of voids. The pre-set grouting holes and venting holes at the top allow air to escape smoothly from the cavity during injection, preventing air stagnation and void formation. The bottom grouting method utilizes gravity to fill the filler from bottom to top, ensuring uniform filling. Simultaneous vibration (attached or inserted) eliminates air bubbles in the filler, enhancing its density. Especially since the polymer mortar or concrete itself has high strength and durability, after dense filling, it can form a stable three-in-one structure with the corrugated steel plate and the old lining, avoiding stress concentration caused by local voids that could lead to damage to the reinforcement layer. S7. Curing and final anchoring: Water-retaining curing is carried out on the grouted filler area, and the nuts at all anchor ends are finally tightened to connect the steel corrugated plate, the geopolymer filler layer and the original lining into a whole; water-retaining curing provides a suitable hydration environment for the geopolymer filler, promotes its continuous strength growth, and avoids insufficient strength or cracks in the filler due to improper curing.

[0019] Furthermore, the specific steps in S1 include: a. 3D laser scanning and data acquisition: A 3D laser scanner is used to perform a full-section scan of the tunnel reinforcement section to obtain point cloud data; the section scan can cover all parts of the tunnel reinforcement section, avoiding omissions in local scans; b. Point cloud data processing and defect identification: Import point cloud data into processing software (such as CloudCompare, Revit) and automatically identify defects by comparing the design model with the measured data; professional processing software can realize rapid comparison between the design model and the measured data, and automatically filter out defect areas such as deformation, cracks, and spalling through algorithms. Compared with manual visual identification, it not only greatly improves the identification efficiency, but also accurately quantifies defect parameters (such as deformation and crack width), avoiding the omission of minor defects and misjudgment of the degree of defects in manual identification; c. BIM Model Construction and Determination of Surgical Removal Boundary: A BIM model of the reinforced section is established. Based on the defect identification results, the removal boundary is determined using the "minimum removal principle". The BIM model has the characteristics of visualization and parameterization, which can intuitively show the relationship between the defect location and the original lining structure. d. Arrange anchors in a quincunx pattern in the BIM model: circumferential spacing of 500-1000mm and longitudinal spacing of 500-1000mm, avoiding the original lining main reinforcement positions, ensuring that the anchor embedment depth is ≥100mm, accurately lay out on site, and use a total station to project the boundary lines and anchor positions in the BIM model onto the lining surface; the quincunx arrangement ensures that the anchors are evenly distributed on the lining surface, which can evenly distribute the external force transmitted by the corrugated steel plate to the original lining, and avoid excessive stress on local anchors; e. Use different colored ink lines to distinguish them; f. Digital verification: Use a portable scanner to verify the layout results. Deviation control: Positioning error ≤ 5mm, and generate a "Precise Positioning Acceptance Report".

[0020] Furthermore, the defects include: areas of excessive lining deformation (deformation > 50 mm), crack distribution network (width > 0.3 mm), and areas of concrete spalling (depth > 30 mm).

[0021] Furthermore, the density of the point cloud data obtained in step a is ≥500 points / m². 2 The accuracy requirement is ±2mm; the point cloud data density is ≥500 points / m². 2 The high standard of ±2mm accuracy ensures that the data can truly reflect the actual shape of the tunnel lining, providing accurate data support for subsequent comparison with the design model to identify defects and reducing the error in defect identification.

[0022] Furthermore, the "minimum excision principle" in step c includes: the boundary should extend at least 100mm beyond the outer edge of the diseased area, the boundary line should be a regular geometric shape (rectangle, trapezoid), the distance between adjacent excision areas should be ≥500mm, and the anchor placement should be digitally designed.

[0023] Furthermore, in step e, different colored ink lines are used to distinguish the concrete cutting boundary line (red), anchor center position (blue), and quality control checkpoint (green). The clear color distinction between red (cutting boundary), blue (anchor position), and green (quality control point) enables construction personnel to quickly identify the requirements of different construction parts and accurately position them during cutting, drilling, and other operations. This avoids problems such as cutting deviation and anchor misalignment caused by confusion in markings. At the same time, the green quality control point facilitates quality inspection and verification during the construction process, improving the efficiency of construction quality control.

[0024] Furthermore, the low-vibration equipment used in S2 includes hydraulic chainsaws, wire saws, or silent crushers. Hydraulic chainsaws, wire saws, silent crushers, and other equipment operate through mechanical cutting or low-impact crushing methods, and their vibration frequency and amplitude are much lower than those of traditional pneumatic picks and other equipment. This can effectively avoid fatigue damage to the original intact lining area caused by vibration and prevent the occurrence of new cracks or deformations.

[0025] Furthermore, when cutting the damaged concrete in S2, the "segmented, skip-section" approach is adopted, that is, only a limited section of concrete is cut at a time. After the cut section is backfilled and reinforced, the construction of the adjacent section is carried out to ensure the overall stability of the tunnel structure. Reference Figure 2 , Figure 2 In the diagram, H indicates the area that has been removed; "+---------+" indicates a single construction section (2-3m in length); "||" indicates the lining to be retained; "→" indicates the direction of construction progress. The skip-section construction sequence is: A→D→E→H→B→C→F→G, to ensure that adjacent sections are not constructed at the same time and to maintain structural stability.

[0026] Furthermore, the filler in S6 uses fly ash-steel slag geopolymer mortar or concrete; geopolymer materials have the characteristics of high strength, high impermeability, and high durability, and their mechanical properties are superior to traditional cement-based materials, which can better withstand the pressure of surrounding rock and environmental erosion; the reuse of fly ash and steel slag as industrial waste not only reduces material costs but also reduces solid waste emissions, which meets environmental protection requirements.

[0027] Furthermore, in S7, the final tightening of the nuts at all anchor ends is carried out after the strength of the geopolymer filler has reached more than 75% of the design value; the final anchoring is carried out after the filler strength has reached more than 75% of the design value, which can avoid premature tightening of the nuts and causing the filler to be deformed under pressure.

[0028] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] Obviously, the embodiments described above are merely some embodiments of the present invention, not all embodiments. The accompanying drawings show preferred embodiments of the present invention, but do not limit the patent scope of the present invention. The present invention can be implemented in many different forms; rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing specific embodiments, or make equivalent substitutions for some of the technical features. Any equivalent structures made using the content of this specification and drawings, directly or indirectly applied to other related technical fields, are similarly within the patent protection scope of this invention.

Claims

1. A rapid construction method for partial replacement of old tunnel lining combined with corrugated steel plate reinforcement, characterized in that, Includes the following sequential steps: S1. Precise positioning and marking: collect point cloud data of the tunnel reinforcement section, identify the diseased area after processing, construct a BIM model and determine the cutting boundary and anchor layout, and perform digital verification after on-site layout; based on the tunnel inspection results, accurately mark the boundary of the concrete area to be cut on the lining surface, and mark the drilling position of the steel corrugated plate anchor at the same time. S2. Segmented skip-concrete removal: Low-vibration equipment is used to cut the damaged concrete along the boundary of the area to be removed. S3. Interface treatment and rebar installation: roughen and clean the old concrete interface exposed after removal to expose a solid base layer. Remove rust from the exposed rebar in the original lining and weld or tie new reinforcing rebars using rebar installation technology to form a rebar skeleton that combines the old and new. S4. Anchor nails are pre-installed. Drill holes at the marked locations of the corrugated steel plate anchor nails. After cleaning the holes, use a chemical anchoring agent to pre-install the anchor nails into the stable part of the original tunnel lining. S5. Positioning and assembly of corrugated steel plates: The prefabricated arc-shaped corrugated steel plates are hoisted to the predetermined position, and the reserved holes on them are passed through the ends of the pre-installed anchors. High-strength bolts are used to assemble and connect adjacent plates from the tunnel arch waist to the arch top to form a complete annular lining. S6. Filling and Vibration: Grouting holes and venting holes are pre-set on the top of the corrugated steel plate. The pre-prepared filler is injected into the cavity formed by the corrugated steel plate and the old lining surface through the bottom grouting hole using a pumping device. At the same time, an attached vibrator is used to vibrate the outer wall of the corrugated steel plate, or an insert vibrator is inserted through the reserved hole. S7. Curing and final anchoring: Water-retaining curing is carried out on the grouted filler area, and the nuts at all anchor ends are finally tightened to connect the steel corrugated plate, the geopolymer filling layer and the original lining into a whole.

2. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 1, characterized in that, The specific steps in S1 include: a. 3D laser scanning and data acquisition: A 3D laser scanner is used to perform a full-section scan of the tunnel reinforcement section to acquire point cloud data; b. Point cloud data processing and disease identification: Import point cloud data into processing software and automatically identify diseases by comparing the design model with the measured data; c. BIM Model Construction and Determination of Surgical Resection Boundary: Establish a BIM model of the reinforced section, and determine the resection boundary based on the disease identification results using the "minimum resection principle"; d. Arrange anchors in a quincunx pattern in the BIM model: circumferential spacing of 500-1000mm and longitudinal spacing of 500-1000mm, avoiding the original lining main reinforcement positions, ensuring that the anchor embedment depth is ≥100mm, accurately lay out on site, and use a total station to project the boundary lines and anchor positions in the BIM model onto the lining surface. e. Use different colored ink lines to distinguish them; f. Digital verification: Use a portable scanner to verify the layout results. Deviation control: Positioning error ≤ 5mm, and generate a "Precise Positioning Acceptance Report".

3. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 2, characterized in that, The defects include: areas of excessive lining deformation (deformation > 50 mm), crack distribution network (width > 0.3 mm), and areas of concrete spalling (depth > 30 mm).

4. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 2, characterized in that, In step a, the density of the point cloud data obtained is ≥500 points / m. 2 The accuracy requirement is ±2mm.

5. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 2, characterized in that, The "minimum excision principle" in step c includes: the boundary should extend at least 100mm beyond the outer edge of the diseased area, the boundary line should be a regular geometric shape (rectangle, trapezoid), the distance between adjacent excision areas should be ≥500mm, and the digital design of anchor placement.

6. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 2, characterized in that, In step e, when different colored ink lines are used to distinguish the concrete cutting boundary line, the blue line represents the center position of the anchor nail, and the green line represents the quality control checkpoint.

7. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 1, characterized in that, The low-vibration equipment used in S2 includes hydraulic chainsaws, wire saws, or silent crushers.

8. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 1, characterized in that, When cutting damaged concrete in S2, a "segmented, skip-section" approach is adopted. That is, only a limited section of concrete is cut at a time. After the cut section is backfilled and reinforced, the construction of the adjacent section is carried out to ensure the overall stability of the tunnel structure.

9. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 1, characterized in that, In S6, the filler material is either fly ash-steel slag polymer mortar or concrete.

10. The rapid construction method for partial replacement of old tunnel lining and composite reinforcement with corrugated steel plates according to claim 1, characterized in that, In S7, the final tightening of the nuts at all anchor ends is performed after the strength of the geopolymer filler has reached more than 75% of the design value.

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