Corrugated steel plate support structure for arch of large-section tunnel and its construction method

Abstract

This invention relates to the field of tunnel and underground engineering support structure technology, and particularly to an arch corrugated steel plate support structure suitable for large-section tunnels and its construction method. The structure includes a first corrugated steel plate and a second and third corrugated steel plate respectively disposed at a first and a second end opposite to the first corrugated steel plate. Multiple sets of adjusting members are provided at both the first and second ends of the first corrugated steel plate. Fixing members are provided at one end of the second and third corrugated steel plates, respectively. The second corrugated steel plate is connected to any set of adjusting members at the first end of the first corrugated steel plate via its fixing members, and the third corrugated steel plate is connected to any set of adjusting members at the second end of the first corrugated steel plate via its fixing members, thereby selecting the overlap between the second and first corrugated steel plates and between the third and first corrugated steel plates. The folding design of this invention reduces the transport width by 40%-60%, solving the bottleneck problem of highway transportation of ultra-large components.

Description

Technical Field

[0001] This invention relates to the field of tunnel and underground engineering support structure technology, and in particular to an arch corrugated steel plate support structure suitable for large-section tunnels and its construction method. Background Technology

[0002] In tunnel engineering, corrugated steel sheets, as a lightweight and high-strength support structure, are widely used in the initial support of tunnels. Traditional corrugated steel sheets are typically designed as integral or segmented units, but in large-section tunnel engineering, these traditional structures have the following problems: (1) Transportation difficulties: The corrugated steel plates required for large-section tunnels are large in size. When transporting them as a whole, they are subject to road width and height restrictions, requiring special transport vehicles and routes, which are costly and inefficient.

[0003] (2) Inconvenient installation and adjustment: The shape of the tunnel cross section often deviates from the design in actual construction. The traditional corrugated steel plate has limited adjustment capabilities and is difficult to fully fit the tunnel outline during installation, which affects the support effect.

[0004] (3) Low construction efficiency: Traditional steel corrugated plate installation requires multiple adjustments, cutting and welding, which is complicated and has a long construction cycle.

[0005] (4) Poor adaptability: Different sizes of corrugated steel plates need to be customized for tunnels with different cross-sectional shapes, resulting in poor versatility.

[0006] To address the aforementioned issues, some adjustable corrugated steel plate structures have been proposed in the prior art, but most of these structures are complex, have limited adjustment ranges, and fail to effectively solve the problems of transportation and installation efficiency. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide an arch corrugated steel plate support structure suitable for large-section tunnels and its construction method.

[0008] The objective of this invention is achieved through the following technical solution: A corrugated steel plate support structure for the arch of a large-section tunnel includes a first corrugated steel plate and a second and a third corrugated steel plate respectively disposed at a first end and a second end opposite to the first corrugated steel plate. The first and second ends of the first corrugated steel plate are each provided with multiple sets of adjusting components; One end of the second corrugated steel plate and one end of the third corrugated steel plate are respectively provided with a fixing member. The second corrugated steel plate is connected to any set of adjusting members at the first end of the first corrugated steel plate through its fixing member. The third corrugated steel plate is connected to any set of adjusting members at the second end of the first corrugated steel plate through its fixing member, so as to select the overlap amount between the second corrugated steel plate and the first corrugated steel plate, and between the third corrugated steel plate and the first corrugated steel plate. In the transport state, the second corrugated steel plate and the third corrugated steel plate can be folded toward the first corrugated steel plate; When in use, the second and third corrugated steel plates unfold and form an arched structure.

[0009] Furthermore, each set of adjusting components includes multiple coaxially arranged adjustable nuts.

[0010] Furthermore, the fixing component includes a fixing nut, a connecting bolt, and an adjusting nut. The fixing nut is fixedly mounted on the second corrugated steel plate. When the fixing nut corresponds to any set of adjusting components, the fixing nut and the adjusting nut are coaxial. The fixing nut is connected to the adjusting nut through the connecting bolt and the adjusting nut.

[0011] Furthermore, a positioning post is fixedly connected to the outside of the fixing nut.

[0012] Furthermore, the second and third corrugated steel plates are each provided with multiple sets of clearance grooves corresponding to the adjusting components, and the clearance grooves are used to accommodate the adjustable nuts.

[0013] Furthermore, the adjustable nut is welded and fixed to the first corrugated steel plate, and the fixed nut is welded and fixed to the second corrugated steel plate.

[0014] Furthermore, the positioning post is fixedly installed at the center of the trough of the second corrugated steel plate.

[0015] Furthermore, the clearance groove is a rectangular groove structure.

[0016] A construction method based on the aforementioned corrugated steel plate support structure for arches of large-section tunnels includes the following steps: Precast corrugated plate assembly: a first corrugated steel plate, a second corrugated steel plate, and a third corrugated steel plate are precast, and multiple sets of adjusting components are fixed on the first and second ends of the first corrugated steel plate after it is formed; fixing components and multiple sets of clearance grooves corresponding to the adjusting components are provided on the second and third corrugated steel plates. Folding and transporting: Fold the ends of the second and third corrugated steel plates without fixing parts inwards respectively; connect the ends of the second and third corrugated steel plates with fixing parts to the corresponding adjusting parts through the fixing parts respectively; load and transport the folded second, third, and first corrugated steel plates as a whole; On-site installation and adjustment: After removing the fixing parts at the tunnel construction site, unfold the corrugated steel plate and put it into preliminary position; according to the actual cross-sectional dimensions of the tunnel, select one set of adjustment parts on the first corrugated steel plate as the target connection point; Connection and fixing: After selection, align the fixing nut and the adjustable nut coaxially, and tighten them with connecting bolts and adjusting nuts.

[0017] The beneficial effects of this invention are: 1) The folding design of this invention reduces the transport width by 40%-60%, solving the bottleneck problem of road transport of oversized components.

[0018] 2) Significantly enhanced adjustment capability: Compared with single or double rows, the three-row adjustment design provides more adjustment levels and a larger adjustment range, which can more precisely and widely adapt to the uncertainty and design changes of the tunnel excavation cross section.

[0019] 3) High installation accuracy and reliability: The matching design of the clearance groove and multi-row nuts ensures the integrity of the structure and the directness of force transmission at any adjustment level, avoiding on-site welding or cutting, and ensuring stable and controllable installation quality.

[0020] 4) Wide applicability: Through the system's geometric design, discrete nut connection points are scientifically associated with the adaptation requirements of continuous tunnel cross sections. One set of components can cover a wider range of engineering applications and is more economical.

[0021] 5) Highly efficient and environmentally friendly construction: All components are assembled, which makes construction fast and allows for reuse of components, in line with the direction of industrialized and green construction. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the corrugated steel plate support structure for the arch of a large-section tunnel, as described in an embodiment of the present invention. Figure 2 This is a three-dimensional view of a corrugated steel plate support structure for arch tunnels in a folded state, suitable for large-section tunnels. Figure 3 This is a schematic diagram showing the connection relationship between the adjusting component and the fixing component; Figure 4 This is a schematic diagram showing the connection relationship between the adjusting and fixing components when viewed from below. Figure 5 A schematic diagram showing the connection between the second corrugated steel plate and the first corrugated steel plate via the innermost connector. In the diagram, 1 is the second corrugated steel plate; 2 is the first corrugated steel plate; 3 is the third corrugated steel plate; 4 is the positioning post; 5 is the fixing nut; 6 is the adjustable nut; 7 is the connecting bolt; 8 is the adjusting nut; and 9 is the clearance groove. Detailed Implementation

[0023] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. 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 are within the scope of protection of the present invention.

[0024] See Figures 1-5 The present invention provides a technical solution: Example

[0025] like Figures 1-5 As shown, an arch corrugated steel plate support structure suitable for large-section tunnels includes a first corrugated steel plate 2 and a second corrugated steel plate 1 and a third corrugated steel plate 3 respectively disposed at a first end and a second end opposite to the first corrugated steel plate 2. The first corrugated steel plate 2 is provided with multiple sets of adjusting components at both its first and second ends. Each set of adjusting components includes multiple coaxially arranged adjustable nuts 6, which are welded and fixed to the first corrugated steel plate 2.

[0026] One end of the second corrugated steel plate 1 and one end of the third corrugated steel plate 3 are respectively provided with fixing members. The second corrugated steel plate 1 is connected to any set of adjusting members at the first end of the first corrugated steel plate 2 through its fixing members. The third corrugated steel plate 3 is connected to any set of adjusting members at the second end of the first corrugated steel plate 2 through its fixing members, so as to select the overlap between the second corrugated steel plate 1 and the first corrugated steel plate 2, and between the third corrugated steel plate 3 and the first corrugated steel plate 2, thereby adjusting the overall effective arc length and radius of curvature of the arch assembled by the first, second and third corrugated steel plates 3.

[0027] The fasteners include a fixing nut 5, a connecting bolt 7, and an adjusting nut 8. The fixing nut 5 is welded and fixedly mounted on the second corrugated steel plate 1. A positioning post 4 is fixedly connected to the outside of the fixing nut 5. When the fixing nut 5 corresponds to any set of adjusting components, the fixing nut 5 and the adjusting nut 6 are coaxial. The fixing nut 5 is connected to the adjusting nut 6 through the connecting bolt 7 and the adjusting nut 8. The positioning post 4 is welded and fixedly mounted at the center of the trough of the second corrugated steel plate 1. The fixing method of the fasteners on the third corrugated steel plate 3 is the same and will not be described in detail here. The second corrugated steel plate 1 and the third corrugated steel plate 3 are symmetrically arranged with the center of the first corrugated steel plate 2 as the axis of symmetry.

[0028] like Figure 2As shown, in the transport state, the second corrugated steel plate 1 and the third corrugated steel plate 3 can be folded toward the first corrugated steel plate 2; like Figure 1 As shown, in the usage state, the second corrugated steel plate 1 and the third corrugated steel plate 3 unfold and form an arched structure.

[0029] The second corrugated steel plate 1 and the third corrugated steel plate 3 are respectively provided with multiple sets of rectangular groove structures 9 corresponding to the adjusting components (the length direction is along the longitudinal direction of the corrugated steel plate), and the grooves 9 are used to accommodate the adjustable nut 6.

[0030] The function of the clearance groove 9 is to provide spatial tolerance. When the fixing nut 5 needs to be connected to the inner column (such as B or C below), the whole nut assembly of the outer column (such as column A) that is "crossed" will extend into these clearance grooves 9, thereby ensuring that the left and right half plates and the middle plate can achieve a tight fit without interference and ensure uniform force distribution.

[0031] Before use, the first corrugated steel plate 2, the second corrugated steel plate 1, and the third corrugated steel plate 3 are pre-formed, and multiple sets of adjusting components are fixed on the first and second ends of the first corrugated steel plate 2 after forming. Fixing components and multiple sets of clearance grooves 9 corresponding to the adjusting components are set on the second corrugated steel plate 1 and the third corrugated steel plate 3. Mid-journey transportation: Fold the ends of the second corrugated steel plate 1 and the third corrugated steel plate 3 without fixing parts inward respectively; connect the ends of the second corrugated steel plate 1 and the third corrugated steel plate 3 with fixing parts to the corresponding adjusting parts through the fixing parts respectively; load and transport the folded second corrugated steel plate 1, the third corrugated steel plate 3, and the first corrugated steel plate 2 as a whole; Finally, after removing the fasteners at the tunnel construction site, the corrugated steel plate is unfolded and initially positioned; based on the actual cross-sectional dimensions of the tunnel, one set of adjusting components on the first corrugated steel plate 2 is selected as the target connection point; After selection, align the fixed nut 5 and the adjustable nut 6 coaxially, and tighten them using the connecting bolt 7 and the adjusting nut 8.

[0032] For ease of subsequent description and understanding, this embodiment provides three groups of adjustment components, each group designated A, B, and C. From the outside in, they are defined as the first column (A), the second column (B), and the third column (C), as follows: Figure 4 , Figure 5 As shown, from left to right, they are A, B, and C. In this embodiment, each column consists of 3-5 adjustable nuts.

[0033] The three to five longitudinally distributed adjustable nuts in each column are not for longitudinal fine-tuning, but rather to enhance the reliability and load-bearing capacity of the single-position connection. These nuts are simultaneously passed through and tightened by the same row of connecting bolts during connection, which is equivalent to changing a single-point hinge to a multi-point parallel linear hinge. This greatly improves the shear resistance and overall stability of the connection node, and enables a leap in structural stiffness between adjustment positions, rather than a continuous change.

[0034] This invention enables a stepped change in the overlap (Δ) between the second and third corrugated steel plates and the first corrugated steel plate by selecting different groups (A, B, C) of adjustment components. This systematically alters the effective inner arc length (Leff) and theoretical radius of curvature (Reff) of the assembled arch, with the following relationship: Leff = Lc + 2Ls - 2Δ, where Lc is the designed inner arc length of the first corrugated steel plate, and Ls is the designed inner arc length of the second or third corrugated steel plate.

[0035] The three sets of adjustment components (A, B, C) offer a wider range of overlap (Δ) options. Each connection selection corresponds to a specific effective installation radius (Reff) based on a preset geometric relationship (Leff = Lc + 2Ls - 2Δ). The three-column design expands the range of adaptable tunnel cross-section radii (Rmin ~ Rmax) and improves adjustment accuracy.

[0036] The inner diameter of the fixing nut 5 is larger than the outer diameter of the connecting bolt. Therefore, the connecting bolt is connected to either the fixing nut 5 or the adjusting nut 8 depending on the state. During transportation and rotation, the connecting bolt 7 is connected to the fixing nut 5 as a common connecting and rotating pair. After unfolding to the correct position, the connecting bolt 7 is pulled out and connected to the adjusting nut 8 for position marking. This achieves both the folding function of the left and right halves of the plate and serves as the final load-bearing connector, simplifying the structure and integrating functions.

[0037] Δ: Overlap amount (in meters). This refers to the change in arc length of the overlapping portion between the single-sided half-plate (second or third corrugated plate) and the middle plate (first corrugated plate) caused by selecting different columns / groups of adjusting components. When the fixing nut is connected to the outermost first column, the baseline overlap amount Δ_A = 0 is defined.

[0038] δ_B, δ_C: Column offset (in meters). These refer to the fixed arc length offset of the axes of the second (B) and third (C) columns relative to the axis of the first (A) column towards the inside of the corrugated steel plate. This is a design constant, δ_C > δ_B > 0.

[0039] L_eff: The actual effective inner arc length of the assembled arch (in meters).

[0040] R_d: Design inner radius of the tunnel arch (in meters).

[0041] R_eff: The actual effective installation inner radius of the assembled arch (in meters).

[0042] θ: The central angle corresponding to the corrugated steel plate of the arch (in radians). It is determined by the tunnel cross-section design and is a constant value.

[0043] Mathematical relationships in the regulation process: When the fixing nut is selected to connect with the adjusting member of a different column, the corresponding overlap Δ is: Connect to the first column (6A): Δ = Δ_A = 0; Connect to the second column (6B): Δ = Δ_B = δ_B; Connect to the third column (6C): Δ = Δ_C = δ_C; At this point, the formula for the effective inner arc length of the assembled arch is: L_eff = L_c + 2L_s - 2Δ (1); Based on the geometric relationship of the circular arc L_eff = R_eff × θ, substituting into Formula 1, we can obtain the core formula for adjustment: R_ × Δ (2; Let the design radius R_, and the constant k = 2 / θ, then Equation 2 simplifies to a clear linear relationship: R_eff = R_d - k × Δ (3); Formula 3 establishes a direct, calculable mapping relationship between gear (adjustment) selection (determining Δ) and installation effect (determining R_eff). By setting δ_B and δ_C during design, three explicit, discrete effective installation radius values ​​are predetermined: R_eff_A = R_d (select column A); R_eff_B = R_d - k × δ_B (Select column B); R_eff_C = R_d - k × δ_C (select column C); Therefore, on-site adjustment is simplified to a "table selection" process: measure the actual required radius R_required, select the closest value from R_eff_A, R_eff_B, and R_eff_C, and then connect the corresponding nut column. Example

[0044] This embodiment is a construction method for the arch corrugated steel plate support structure suitable for large-section tunnels, based on the method described in Embodiment 1, and includes the following steps: Precast corrugated plate assembly: A first corrugated steel plate, a second corrugated steel plate, and a third corrugated steel plate are precast, and multiple sets of adjusting components are fixed to the first and second ends of the formed first corrugated steel plate. Fixing components and multiple sets of clearance grooves corresponding to the adjusting components are installed on the second and third corrugated steel plates. The specific process is as follows: Determine R_d and θ based on the tunnel design drawings.

[0045] Based on the geological report and construction specifications, the possible fluctuation range of the tunnel cross-section is estimated, and the minimum radius R_min that needs to be covered is determined.

[0046] The maximum overlap Δ_ required is calculated from R_min.

[0047] Allocate Δ_max reasonably and design two adjustment offsets δ_B and δ_C (for example, δ_B = Δ_max * 0.4, δ_C = Δ_max * 0.8).

[0048] Based on δ_B and δ_C, three rows of integral adjustment components (A, B, C) are precisely positioned and welded on the first corrugated steel plate, each row containing four longitudinally aligned adjustable nuts.

[0049] Based on the projection position of the adjusting component, corresponding clearance grooves are CNC machined on the second and third corrugated steel plates.

[0050] Calculate and generate the "Gear-Radius Correspondence Table": clearly indicate the theoretical installation radii R_eff_A, R_eff_B, and R_eff_C corresponding to columns 6A, 6B, and 6C, respectively.

[0051] Folding and transporting: Fold the ends of the second and third corrugated steel plates without fixing parts inwards respectively. Connect the ends of the second and third corrugated steel plates with fixing parts to the corresponding adjusting parts through the fixing parts and tighten the adjusting nuts to the transport state. Load and transport the folded second, third, and first corrugated steel plates as a whole. The overall transport width is reduced to about half of the original width.

[0052] On-site installation and adjustment: After removing the fixing components at the tunnel construction site, unfold the corrugated steel plate and initially position it; based on the actual cross-sectional dimensions of the tunnel, select one set of adjusting components on the first corrugated steel plate as the target connection point. The specific process is as follows: Deployment and hoisting: Deploy the second and third corrugated steel plates at the tunnel face and hoist them as a whole to the arch.

[0053] Cross-section measurement: Using equipment such as laser profilers, the excavation outline is quickly scanned, and the average actual radius R_actual of the current cross-section is calculated.

[0054] Select the appropriate nut column by referring to the "Gear-Radius Correspondence Table" and choosing the nut column that corresponds to the theoretical radius value closest to R_actual (for example, if R_actual is between R_eff_B and R_eff_C, then choose the closer column 6B or 6C).

[0055] Disassembly and Reconnection: Remove the connecting bolts from the shipping state. Pass a new set of high-strength bolts sequentially through: the retaining nut, the clearance slot group, and all the adjustable nuts in the selected target column (e.g., column B). Then install and initially tighten the adjusting nut.

[0056] Final tightening: Using a hydraulic torque wrench, tighten all adjusting nuts to the designed torque in a symmetrical sequence. At this point, since the clearance groove has a certain length allowance in the longitudinal direction, a final millimeter-level fine adjustment can be made to ensure a perfect fit of the arch ring.

[0057] Quality inspection: Check the torque of all bolts and the gap between the arch profile and the rock surface.

[0058] The above description is merely a preferred embodiment of the present invention. It should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the concept described herein through the above teachings or related technical or knowledge. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A corrugated steel plate support structure for the arch of a large-section tunnel, characterized in that: It includes a first corrugated steel plate and a second corrugated steel plate and a third corrugated steel plate respectively disposed at a first end and a second end opposite to the first corrugated steel plate; The first and second ends of the first corrugated steel plate are each provided with multiple sets of adjusting components; One end of the second corrugated steel plate and one end of the third corrugated steel plate are respectively provided with a fixing member. The second corrugated steel plate is connected to any set of adjusting members at the first end of the first corrugated steel plate through its fixing member. The third corrugated steel plate is connected to any set of adjusting members at the second end of the first corrugated steel plate through its fixing member, so as to select the overlap amount between the second corrugated steel plate and the first corrugated steel plate, and between the third corrugated steel plate and the first corrugated steel plate. In the transport state, the second corrugated steel plate and the third corrugated steel plate can be folded toward the first corrugated steel plate; When in use, the second and third corrugated steel plates unfold and form an arched structure.

2. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 1, characterized in that: Each set of adjustment components includes multiple coaxially arranged adjustable nuts.

3. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 2, characterized in that: The fastener includes a fixed nut, a connecting bolt, and an adjusting nut. The fixed nut is fixedly mounted on the second corrugated steel plate. When the fixed nut corresponds to any set of adjusting components, the fixed nut and the adjusting nut are coaxial. The fixed nut is connected to the adjusting nut through the connecting bolt and the adjusting nut.

4. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 3, characterized in that: The fixing nut is externally fixedly connected to a positioning post.

5. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 3, characterized in that: The second and third corrugated steel plates are respectively provided with multiple sets of clearance grooves corresponding to the adjusting components, and the clearance grooves are used to accommodate the adjustable nuts.

6. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 3, characterized in that: The adjustable nut is welded and fixed to the first corrugated steel plate, and the fixed nut is welded and fixed to the second corrugated steel plate.

7. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 4, characterized in that: The positioning post is fixedly installed at the center of the trough of the second corrugated steel plate.

8. The corrugated steel plate support structure for the arch of large-section tunnels according to claim 5, characterized in that: The clearance groove is a rectangular groove structure.

9. A construction method for an arch corrugated steel plate support structure suitable for large-section tunnels based on any one of claims 1-8, characterized in that: Includes the following steps: Precast corrugated plate assembly: a first corrugated steel plate, a second corrugated steel plate, and a third corrugated steel plate are precast, and multiple sets of adjusting components are fixed on the first and second ends of the first corrugated steel plate after it is formed; fixing components and multiple sets of clearance grooves corresponding to the adjusting components are provided on the second and third corrugated steel plates. Folding and transporting: Fold the ends of the second and third corrugated steel plates without fixing parts inwards respectively; connect the ends of the second and third corrugated steel plates with fixing parts to the corresponding adjusting parts through the fixing parts respectively; load and transport the folded second, third, and first corrugated steel plates as a whole; On-site installation and adjustment: After removing the fixing parts at the tunnel construction site, unfold the corrugated steel plate and put it into preliminary position; according to the actual cross-sectional dimensions of the tunnel, select one set of adjustment parts on the first corrugated steel plate as the target connection point; Connection and fixing: After selection, align the fixing nut and the adjustable nut coaxially, and tighten them with connecting bolts and adjusting nuts.

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