A method for installing a segmental lining of a shield tunnel

Abstract

The present application relates to the field of shield tunnel construction, and discloses a kind of shield tunnel fabricated lining installation construction method, comprising the following steps: step 1. the lining is designed as the structure of multiple lining blocks butt joint with each other, the annular connection between adjacent lining blocks is connected by CT socket assembly, and the longitudinal connection is connected by threaded steel bar and sleeve;Step 2. cantilever crane, lifting feeder trolley and assembly trolley are sequentially arranged along the shield tunneling direction, the assembly trolley is provided with vacuum suction cup, laser positioning sensor and rounder;Step 3. the installation equipment described in step 2 is used to transport and hoist the lining block, and the lining block is assembled and fixed on the inner arc surface of segment.The method can solve the problems of transportation, hoisting, damage prevention and deformation, high-precision assembly and other difficult problems of large-size lining blocks in the internal space of the tunnel, realize the collaborative work of multiple processes with shield construction, and ensure the construction quality, safety and construction efficiency of the tunnel lining structure.

Description

Technical Field

[0001] This invention relates to the field of shield tunnel construction, and specifically discloses a method for installing prefabricated inner linings in shield tunnels. Background Technology

[0002] In shield tunnel construction, secondary lining is a core component ensuring the overall rigidity, waterproofing, and long-term durability of the tunnel structure, making it an indispensable key process. Traditional secondary lining often employs cast-in-place concrete, which suffers from long construction periods, poor working environments, and difficulties in quality control. In recent years, prefabricated lining structures have been increasingly adopted in tunnel engineering due to their advantages such as fast construction speed and good structural integrity. However, the installation of prefabricated linings within tunnels faces a series of technical challenges: the narrow working space within shield tunnels, the large size and weight of the lining segments, and the difficulties in transportation, hoisting, and maneuvering; the high requirements for joint fit, circumferential seam alignment, and longitudinal seam tightness due to assembly errors in the lining segments; the need for overlapping operations with shield tunneling, segment installation, and material transportation, making construction organization difficult; the use of various types of connectors between lining segments and between the lining and segments, resulting in complex installation, connection, and fastening processes; and the potential for error accumulation during multi-ring continuous assembly, affecting the overall alignment and connection quality of the tunnel lining.

[0003] In the prior art, there are several patent applications concerning tunnel secondary lining construction methods, mechanized assembly equipment, and connection structures between tunnel segments and the inner lining. For example, invention application CN119641389A discloses a tunnel secondary lining construction method and its supporting equipment. This method involves using prefabricated corrugated steel plates to form a closed ring along the tunnel's circumference, creating pre-drilled holes at the connection points to enclose temporary supports, installing embedded components, and pouring concrete. After the lining reaches its design strength, the temporary supports are cut and the holes are sealed, thus achieving secondary lining construction without removing the temporary supports. Invention application CN120990650A discloses a tunnel and mine construction lining trolley, including a guide rail, a traveling platform, an automatic feeding mechanism, and a hydraulic rounding device, enabling efficient assembly and construction of prefabricated secondary lining plates in a mechanized and intelligent manner. Invention application CN118423092A discloses a connection structure and construction method for shield tunnel segments and prefabricated linings. It achieves a reliable connection between the segments and the lining through methods such as fully threaded steel bars, connecting components, pre-embedded connectors, and pre-embedded steel plates. This connection can adapt to gap changes caused by the elliptical deformation of the segments, ensuring a stable connection between the shield tunnel segments and the lining structure. Furthermore, invention application CN110043293A discloses a socket-type tunnel early-strength support system and its installation method. This system uses a plug-in structure to achieve circumferential and longitudinal connections between tunnel support segments. However, this plug-in structure is a rigid connection where the plug and slot directly meet. Precise alignment is required during installation, and there is no adjustment margin, resulting in poor adaptability. Moreover, it only provides the connection function and cannot accommodate the need for full-circle adjustment.

[0004] A comprehensive analysis of the aforementioned documents reveals that existing application documents primarily employ circumferential or longitudinal screw connections for connection structures. These connections suffer from cumbersome installation, difficulty in controlling docking accuracy, and an inability to accommodate minor segment deformations. Existing mechanized equipment is largely single-function designed, failing to create an integrated equipment system suitable for the transportation, hoisting, orientation conversion, feeding, and assembly of lining segments within narrow tunnel spaces. This results in low operational efficiency in confined tunnels. Furthermore, the pallets used for transporting and storing lining segments lack specific design considerations, leading to difficulties in gripping and segment deformation. In addition, existing technologies include socket-type tunnel support structures, such as the interlocking socket structure used in invention application CN110043293A. While this achieves interlocking assembly, it suffers from difficulties in post-assembly circular adjustment, high pre-installation accuracy requirements, inability to accommodate minor segment deformations, and poor control of assembly gaps. Moreover, it lacks integrated circular alignment functionality, requiring additional steps for circular alignment correction, making the installation process cumbersome.

[0005] Although existing technologies have made improvements in the construction process, single equipment, or connecting components of secondary tunnel lining, a complete collaborative construction method for prefabricated linings in large-diameter shield tunnels has not yet been formed. Especially in complex environments where the working space inside the tunnel is extremely limited, the lining blocks are large, the assembly accuracy requirements are high, and multiple processes such as excavation, segment installation, and material transportation need to be carried out simultaneously, existing technologies are difficult to meet the needs of efficient and precise construction. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a prefabricated lining installation method for shield tunnels. This method solves the problems of transporting, hoisting, preventing damage and deformation, and high-precision assembly of large-sized lining blocks within the tunnel interior space. It enables collaborative operation with multiple shield tunneling processes, ensuring the construction quality, safety, and efficiency of the tunnel lining structure.

[0007] A method for installing prefabricated inner lining in a shield tunnel includes the following steps: Step 1. Design the lining structure: The lining is designed as a structure of multiple lining blocks that are connected to each other. The circumferential connection between adjacent lining blocks is achieved through a CT-shaped socket assembly, and the longitudinal connection between adjacent lining blocks is achieved through a threaded steel bar and a sleeve. The CT-shaped socket assembly includes a C-shaped part and a T-shaped part. The insertion port of the C-shaped part is located on the longitudinal mating surface of the lining block. The T-shaped part is provided with an arc-shaped adjusting boss, and the C-shaped part is provided with an arc-shaped groove that mates with the arc-shaped adjusting boss. The arc-shaped adjusting boss can be radially fine-tuned within the arc-shaped groove to achieve real-time full-circle correction of the lining blocks. Step 2. Layout of complete set of installation equipment: Along the tunnel boring direction, a cantilever crane, a lifting feeding trolley and an assembly trolley are set up in sequence. The cantilever crane is equipped with a clamping lifting device, and the assembly trolley is equipped with a vacuum suction cup, a laser positioning sensor and a rounding device. Step 3. Use the installation equipment described in Step 2 to transport and hoist the inner lining segments, and assemble and fix the inner lining segments to the inner arc surface of the tube segment; after each assembly distance, activate a spare ring, in which the adjustment gap of the CT-shaped socket assembly is greater than the adjustment gap of the CT-shaped socket assembly in other inner lining rings.

[0008] Preferably, a spare ring is activated after each assembly has accumulated 150m.

[0009] Preferably, in step 1, the circumferential connection ends of two adjacent inner lining blocks are provided with L-shaped connection notches.

[0010] Preferably, in step 1, the arc-shaped adjusting boss has a radial fine adjustment of ±5° within the arc-shaped slot.

[0011] Preferably, in step 1, the end of the threaded steel bar is provided with a guide taper, and the inner wall of the sleeve is provided with an elastic buffer layer.

[0012] Preferably, in step 1, the outer end face of the inner lining segment is machined with a U-shaped reserved hole. After the inner lining segment is assembled in place, the connecting rod is screwed into the connector on the inner arc surface of the pipe segment through the U-shaped reserved hole. A steel mesh and a multi-layer steel plate assembly are installed outside the connecting rod. The multi-layer steel plate assembly is spliced ​​on site according to the outer arc surface of the inner lining. After being attached to the inner lining segment and the pipe segment, it is welded and fixed to complete the connection between the inner lining segment and the pipe segment.

[0013] Preferably, in step 2, the rounding device is an arc-shaped hydraulic jacking structure, and its jacking end is provided with an arc-shaped jacking plate with the same curvature as the inner arc surface of the liner. The rounding device jacks according to the fine-tuning data of the CT-shaped socket assembly.

[0014] Preferably, in step 3, during the transportation of the inner lining blocks, a tray is provided between two adjacent inner lining blocks. The tray is a horizontal U-shaped structure, with lifting clamping holes at both ends of the U-shaped structure and an isolation groove on the bottom surface of the U-shaped structure.

[0015] Preferably, in step 3, a sealant is used to fill the gap between the arc-shaped groove and the arc-shaped adjusting boss in the CT-shaped socket assembly to achieve the fixed shape of the socket assembly.

[0016] Preferably, in step 3, after every 5 rings of inner lining are assembled, the side ditch foundation is poured and the grouting is used to seal the end of the partition.

[0017] Preferably, in step 3, after the inner lining is installed, the grouting layer is constructed layer by layer from bottom to top, and the thickness of the grouting layer is 35 mm.

[0018] Beneficial effects: 1. This invention utilizes specialized mechanized equipment consisting of a cantilever crane, a lifting feeding trolley, and an assembly trolley, combined with relevant construction techniques, to achieve posture conversion, precise feeding, and six-degree-of-freedom attitude adjustment and installation of the inner lining blocks. This significantly improves assembly efficiency and positioning accuracy, effectively solving the problems of difficult transportation and hoisting of large-sized, heavy-duty inner lining blocks in shield tunnels, as well as their susceptibility to damage and deformation. It is particularly suitable for efficient assembly under limited working conditions inside shield tunnels.

[0019] 2. Compared with existing plug-in connections, the CT-shaped socket assembly with integrated rounding adjustment function has the advantages of high installation efficiency, strong deformation adaptability, and simultaneous assembly and rounding. It also forms a synergistic rounding effect with the rounding device of the assembly trolley, greatly simplifying the installation process and improving rounding efficiency by more than 50%.

[0020] 3. The coordinated operation of the CT-shaped socket assembly and the rounding device achieves "step-by-step rounding with dual protection," solving the technical problem of the difficulty in rounding traditional socket connections.

[0021] 4. The CT-shaped socket assembly with circumferential full-circle adjustment function is integrated with the threaded steel bar and sleeve connector with longitudinal reinforcement connection. Combined with the grouting layer and the splicable multi-layer steel plate assembly, it not only solves the defects of the existing screw connection installation, such as cumbersome installation, difficult precision control and weak deformation resistance, but also improves the adaptability, stability and fit of the connection structure. It ensures the reliable connection between the lining and the segment and the integrity of the structure. Compared with the conventional mechanical connection structure, its deformation adaptability, connection strength and installation convenience are significantly improved.

[0022] 5. Through the triple technical system of "structural self-adjustment + precise equipment control + process error elimination", strict error control and cumulative error elimination are achieved. This system is linked in real time with the process scheduling of shield tunneling, providing solid technical support for the coordinated advancement of multiple processes such as lining assembly, shield tunneling, segment installation, and material transportation. It realizes efficient coordination of multiple processes, improving the overall construction efficiency by more than 40%. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the modular circumferential assembly structure of the prefabricated inner lining in an embodiment of the present invention; Figure 2 This is a schematic diagram of the segmented structure of the left inner lining in an embodiment of the present invention; Figure 3 This is a schematic diagram of the segmented structure of the capping lining in an embodiment of the present invention; Figure 4 This is a schematic diagram of the right-side inner lining block structure in an embodiment of the present invention; Figure 5 This is a schematic diagram of the CT-shaped socket assembly connection in an embodiment of the present invention; Figure 6 This is a schematic diagram of the threaded steel bar and sleeve insertion connection used for the longitudinal connection of the inner lining blocks in an embodiment of the present invention; Figure 7 This is a schematic diagram of the layout of the complete set of installation equipment in an embodiment of the present invention; Figure 8 This is a schematic diagram of the placement structure during the transportation of the inner lining in an embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of the pallet for transporting goods with segmented inner lining in an embodiment of the present invention; Figure 10 This is a schematic diagram of the sealing of the U-shaped pre-reserved holes in the inner lining in an embodiment of the present invention. Figure 1 ; Figure 11 This is a schematic diagram of the sealing of the U-shaped pre-reserved holes in the inner lining in an embodiment of the present invention. Figure 2 ; Figure 12 This is a schematic diagram of the sealing of the U-shaped pre-reserved holes in the inner lining in an embodiment of the present invention. Figure 3 ; Figure 13 This is a schematic diagram of the sealing of the U-shaped pre-reserved holes in the inner lining in an embodiment of the present invention. Figure 4 ; Figure 14 This is a schematic diagram of the sealing of the U-shaped pre-reserved holes in the inner lining in an embodiment of the present invention. Figure 5 ; Figure 15 This is a schematic diagram of the sealing of the U-shaped pre-reserved holes in the inner lining in an embodiment of the present invention. Figure 6 ; Reference numerals: 1-Left side lining section; 2-Top lining section; 3-Right side lining section; 4-Threaded steel bar; 5-Sleeve; 6-T-shaped piece; 7-C-shaped piece; 8-Transport vehicle; 9-Traveling mechanism; 10-Cantilever crane; 11-Traction winch; 12-Clamping lifting device; 13-Bottom pallet; 14-Lifting platform; 15-Lifting feeding trolley; 16-Laser positioning sensor; 17-Vacuum suction cup; 18-Support assembly; 19-Circularizer; 20-Single-layer pallet; 21-Fourth steel plate; 22-Sixth steel plate; 23-Fifth steel plate; 24-First steel plate; 25-Reinforcing mesh; 26-Third steel plate; 27-Second steel plate; 28-Eighth steel plate; 29-Seventh steel plate; 30-Ninth steel plate; 31-Connecting rod; 32-Connector. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments, and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0026] This embodiment provides a method for installing prefabricated inner linings in shield tunnels, mainly including steps such as transporting and storing the inner lining in sections, feeding materials, assembling, and connecting and fixing them. This embodiment incorporates targeted and innovative design layouts for the existing inner lining structure and related mechanical equipment, as detailed below: The lining structure is designed as follows: Figure 1-4The lining consists of at least three standard arc-shaped sections joined together to form a complete lining. Taking these three sections as an example, they are: left lining section 1, capping lining section 2, and right lining section 3. All lining sections are made of C50 reinforced concrete. To improve the crack resistance and toughness of the lining sections, 1.5 kg / m³ of additive is used in the concrete. 3 The lining is made of polypropylene fiber with a permeability grade of P12. Each lining segment is 165mm thick, 2m wide, with an outer diameter of 12.53m and an inner diameter of 12.2m, and weighs approximately 6.7t per segment. The lining segments employ a wedge-shaped structure design with L-shaped connecting notches on both the left and right sides, with a wedge depth of 12mm. During assembly, the wedge structure allows for a maximum relative position adjustment of 12mm along the longitudinal seam between two lining segments, correcting assembly errors and ensuring smoother assembly. The 12mm wedge depth represents the maximum adjustable displacement provided during assembly, primarily used for error correction. All lining segments have pre-embedded grooves on their inner curved surfaces for welding steel plates.

[0027] The various lining sections are interconnected in both the circumferential and longitudinal directions to form a monolithic lining. The circumferential connections are made using methods such as… Figure 5 The CT-shaped socket assembly shown is made of cast steel ZG310-570. This CT-shaped socket assembly integrates a rounding adjustment function: the T-shaped part 6 has an arc-shaped adjustment boss, and the C-shaped part 7 has a matching arc-shaped groove. The arc-shaped adjustment boss of the T-shaped part 6 can be slid into the arc-shaped groove of the C-shaped part 7 to complete the initial positioning. The arc-shaped adjustment boss can be radially fine-tuned within the arc-shaped groove by ±5°, achieving real-time rounding correction of the inner lining segments. This replaces part of the rounding function of the traditional independent rounding device, simplifying the installation process. The installation adjustment gap of the CT-shaped socket assembly is 2.8mm, improving installation efficiency by 30% compared to ordinary circumferential screw connections and 40% compared to interlocking connections. Furthermore, the arc-shaped concave-convex fit structure better adapts to the slight elliptical deformation of the pipe segments, with a deformation adaptation range of up to 5mm, far superior to the defect of interlocking connections that cannot adapt to deformation due to rigid connections. The longitudinal connections between the various lining sections utilize an insertion connection using a φ22mm threaded steel bar 4 and a φ46mm polyamide sleeve 5. Figure 6As shown, the threaded steel bar 4 is a fully threaded steel bar with a guide taper at its end. The inner wall of the sleeve 5 is provided with a buffer layer of elastic material, preferably a rubber buffer layer. After the threaded steel bar 4 is inserted into the sleeve 5, it forms an elastic fit with the sleeve 5. There is a 2mm installation adjustment gap between the threaded steel bar 4 and the sleeve 5, which can absorb the longitudinal deformation stress of the pipe segment and the lining. The combination of circumferential and longitudinal connection methods with a 35mm grouting layer solves the defects of existing screw connections, such as cumbersome installation, difficulty in controlling precision, and weak deformation resistance, as well as the problems of difficulty in achieving a complete circle and poor adaptability of plug-in connections. At the same time, it ensures a reliable connection between the lining and the pipe segment. The connection between the inner lining sections and the existing segments and box culverts abandons the single tie rod connection and adopts a composite fixing structure that combines a multi-layer steel plate assembly with a steel mesh 25. The inner lining sections are designed with U-shaped reserved holes, which provides a larger operating and observation space for the connection operation. The connection structure is connected to the embedded parts in the segments and box culverts through the connector 32 and the connecting tie rod 31. The concentrated force of the connecting tie rod 31 is diffused to the entire inner lining through the multi-layer steel plate assembly and the steel mesh 25, forming a reliable overall force-bearing system.

[0028] To achieve efficient transportation, precise hoisting, and high-precision assembly of the lining sections, this invention designs a dedicated set of mechanized installation equipment, such as... Figure 7 As shown, the system comprises three parts: a cantilever crane 10, a lifting and feeding trolley 15, and an assembly trolley. This system is not a simple superposition of existing single equipment, but rather an integrated collaborative design specifically for the narrow spaces and multi-process overlapping operations in shield tunnel construction. The three parts are functionally closely connected and work together to form a seamless "lifting-transfer-assembly" workflow: the cantilever crane 10 is responsible for lifting and attitude conversion between the transport vehicle 8 and the lifting and feeding trolley 15; the lifting and feeding trolley 15 receives the inner lining blocks and accurately feeds them to the assembly position; and the assembly trolley ultimately completes the high-precision assembly with six degrees of freedom adjustment capability. This effectively solves the problems of incomplete functional coverage and operational conflicts that easily occur in narrow spaces with existing single equipment. Most importantly, the cantilever crane 10 is equipped with a rotatable clamping and lifting device 12. Through coordinated control, the clamping and lifting device 12, along with the six-degree-of-freedom vacuum suction cup 17 and laser positioning sensor 16 on the assembly trolley, can control the attitude adjustment error of the inner lining segments to within 0.5mm. Its overall accuracy far surpasses the level achievable by existing equipment operating independently. Simultaneously, the rounding device 19 of the assembly trolley works in synergy with the integrated rounding function of the CT-shaped socket assembly. First, the CT-shaped socket assembly completes real-time rounding and fine-tuning of individual inner lining segments, and then the rounding device 19 completes the fine-tuning and shaping of the entire inner lining ring. This achieves multiple rounding processes and double protection, significantly simplifying the rounding installation procedure.

[0029] The cantilever crane 10 includes a main body, a traction winch 11, and a clamping device 12. The main body of the cantilever crane 10 is an inverted U-shaped frame structure with a hollow lower section, allowing the transport vehicle 8 to travel close to the lifting feeding trolley 15. The main body of the cantilever crane 10 is made of high-strength steel to ensure the load-bearing capacity and stability of the equipment. The traction winch 11 is equipped with a high-precision speed control system, enabling smooth lifting and lowering of the lining sections. The clamping device 12 is hydraulically driven, possessing reliable clamping force to effectively prevent the lining sections from slipping during lifting. Simultaneously, the clamping device 12 can rotate horizontally to meet the needs of changing the posture of the lining sections. This cantilever crane 10 is mainly used for lifting and changing the posture of lining sections from the transport vehicle 8 to the lifting feeding trolley 15, enabling flexible operation in narrow tunnel spaces.

[0030] The lifting feeding trolley 15 includes a lower mobile transport structure and an upper lifting platform 14, which is a scissor lift structure. The mobile transport structure is equipped with a high-precision walking mechanism 9, which enables the smooth movement and precise positioning of the lifting feeding trolley 15. The lifting platform 14 can realize the temporary storage, height adjustment and feeding of the inner lining blocks. The lifting height of the lifting platform 14 can be adjusted according to construction needs, with a maximum lifting height of 3.5m, which meets the gripping height requirements of the vacuum suction cup 17 on the assembly trolley. Moreover, the overall dimensions of the assembly trolley have been optimized to adapt to the working space requirements inside the tunnel.

[0031] The assembly trolley includes a support assembly 18, a working platform, a rounding device 19 that works in conjunction with the CT-shaped socket assembly, a laser positioning sensor 16, and an assembly robotic arm. The support assembly 18 uses a high-strength hydraulic support to provide stable support for the assembly trolley and ensure overall stability during assembly. The working platform provides a safe and convenient working space for construction personnel. The rounding device 19 is an arc-shaped hydraulic jacking structure with an arc-shaped jacking plate at its jacking end that matches the curvature of the inner arc surface of the liner. It can precisely jack according to the fine-tuning data of the CT-shaped socket assembly, with a jacking stroke of 0–80 mm. This complements the radial fine-tuning function of the CT-shaped socket assembly and, combined with the laser positioning sensor 16, achieves efficient rounding and shaping of the entire ring liner. The assembly robotic arm is equipped with a vacuum suction cup 17 with six degrees of freedom adjustment. This vacuum suction cup 17 can reliably grip the liner segments and, through its six degrees of freedom adjustment function, allow for arbitrary posture adjustment of the liner segments in space, ensuring precise positioning and installation of the liner segments.

[0032] The specific process of using the mechanical equipment laid out in this application to construct the shield tunnel for the inner lining sections designed in this application is as follows: S1. Transportation and storage of the inner lining in sections.

[0033] S1.1, adopting as follows Figure 8and Figure 9 The specialized pallet assembly shown enables the storage and transfer of the inner lining modules. The assembly includes a bottom pallet 13 and a single-layer pallet 20. The bottom pallet 13 is fixed to a double-headed flatbed transport vehicle 8, serving as a stable transport base. The single-layer pallet 20 directly supports each inner lining module, ensuring its stability and integrity during transport. The single-layer pallet 20 features a hollowed-out design in the middle, forming a horizontal U-shaped structure, providing unobstructed gripping space for the vacuum suction cup 17 of the assembly trolley. A limiting guide groove is designed at the center of the bottom surface of the single-layer pallet 20, effectively preventing lateral displacement during transport by precisely fitting with the inner lining modules. Lifting clamping holes are designed at both ends of the single-layer pallet 20, with their spacing specifically calculated to match the force distribution of the clamping device 12 on the cantilever crane 10, thereby evenly distributing the load during lifting and preventing cracking of the inner lining modules due to stress concentration. The inner lining modules are transported to the designated construction location by the double-headed transport vehicle 8.

[0034] S1.2 After the transport vehicle 8 arrives at the designated construction site, adjust the vehicle position to ensure that there is a horizontal rotation space of more than 9.5m between the cantilever crane 10 and the lifting feeding trolley 15. The clamping device 12 on the cantilever crane 10 is lowered to accurately grab a lining segment and its single-layer pallet 20. After the clamping device 12 rises past the lifting feeding trolley 15, it rotates horizontally by 90° to adjust the lining segment to the required posture before installation.

[0035] S1.3 After the lining segments are adjusted, the cantilever crane 10 drives the traveling mechanism 9 to lift the lining segments and single-layer pallets 20 onto the lifting feeding trolley 15 and slowly place them on the lifting platform 14 of the lifting feeding trolley 15. Following the same process, the three lining segments of the same single ring are placed sequentially on the lifting platform 14 using the single-layer pallets 20 below. During the storage process, it is ensured that the lining segments are placed stably without collision or displacement.

[0036] S2, feeding of the inner lining in sections.

[0037] S2.1 After the single-ring inner liner is segmented and stored, the lifting platform 14 on the lifting feeding trolley 15 is activated, raising it 3.5m. This height is the receiving height within the radial travel range of the vacuum suction cup 17. Through the overall movement of the lifting feeding trolley 15, the individual inner liner segment is accurately delivered to the top of the assembly trolley, waiting for the vacuum suction cup 17 to grab it, completing the feeding preparation.

[0038] S2.2 The vacuum suction cups 17 on the assembly trolley extend radially, reliably grabbing and lifting the inner lining segment. Then, the lifting feeding trolley 15 moves backward and lowers the height of the lifting platform 14. The cantilever crane 10 moves forward and lifts away the empty single-layer pallet 20 of the first inner lining segment. After the first inner lining segment is installed and fixed, the conveying and transfer operation of the second inner lining segment begins, and so on in a cycle.

[0039] S3. Assembly of the inner lining in sections.

[0040] S3.1 Assembly of Left Lining Block 1: After the vacuum suction cup 17 of the assembly trolley picks up the left lining block 1, it moves circumferentially on the assembly trolley, rotating the left lining block 1 counterclockwise to the arch waist area to be installed on the left side of the tunnel. The vacuum suction cup 17 moves slowly circumferentially, aligning the threaded steel bar 4 extending from the end face of the left lining block 1 with the sleeve 5 on the end face of the previous ring lining block, while simultaneously adjusting the U-shaped pre-drilled hole on the left lining block 1 to align with the connector 32 pre-embedded on the inner arc surface of the segment. The vacuum suction cup 17 is then finely adjusted along the six degrees of freedom until the center line of the threaded steel bar 4 and the sleeve 5 are aligned, and the inner arc surface of the left lining block 1 in its current position is flush with the inner arc surface of the previous ring lining block. Subsequently, the vacuum suction cup 17 drives the left lining block 1 to move axially ( Figure 2 (As shown by the arrow), insert the threaded steel bar 4 of the left inner lining block 1 completely into the sleeve 5 of the previous inner lining block to achieve temporary fixation. Check to ensure that the grout-blocking strip of the circumferential joint is fully compressed and that the circumferential joint of the inner lining is aligned with the circumferential joint of the segment, confirming that the left inner lining block 1 is assembled in place. Screw the connecting tie rod 31 into the connector 32 on the inner arc surface of the segment through the multiple U-shaped reserved holes of the left inner lining block 1.

[0041] S3.2 Assembly of the inner lining block 2.

[0042] After the vacuum suction cup 17 picks up the capping inner lining segment 2, it moves circumferentially on the assembly trolley, rotating the capping inner lining segment 2 counterclockwise so that its longitudinal seam connection face is close to the longitudinal seam connection face of the left inner lining segment 1, leaving an adjustment space of 10-20cm. The vacuum suction cup 17 moves slowly circumferentially, aligning the CT connector with the arc-shaped adjustment boss or arc-shaped groove at the longitudinal seam connection face of the capping inner lining segment 2 with the CT connector with the arc-shaped groove or arc-shaped adjustment boss at the longitudinal seam connection face of the left inner lining segment 1. Simultaneously, observe the alignment of the threaded steel rod 4 protruding from the end face of the capping inner lining segment 2 with the sleeve 5 on the end face of the previous ring inner lining segment, as well as the alignment of the U-shaped reserved hole on the capping inner lining segment 2 with the connector 32 embedded in the inner arc surface of the segment. The vacuum chuck 17 is adjusted slightly along the six degrees of freedom until the threaded steel rod 4 extending from the end face of the capping inner liner block 2 is aligned with the center line of the sleeve 5 on the end face of the previous ring inner liner block, and the CT connector of the capping inner liner block 2 is still aligned with the CT connector of the left inner liner block 1; then the vacuum chuck 17 drives the capping inner liner block 2 to move axially ( Figure 3 (As shown by the arrow), connect the CT connector of the capping inner lining block 2 to the CT connector of the left inner lining block 1, and simultaneously insert the threaded steel bar 4 of the capping inner lining block 2 completely into the sleeve 5 of the previous inner lining block. Operate the vacuum suction cup 17 for fine adjustment to ensure that the inner arc surface of the current position of the capping inner lining block 2 is flush with the inner arc surface of the previous inner lining block. Check that the circumferential joint grout-blocking strip is fully compressed and that the circumferential joint of the capping inner lining block 2 is aligned with the circumferential joint of the pipe segment, confirming that the capping inner lining block 2 is assembled in place.

[0043] S3.3 Assembly of right side inner lining block 3.

[0044] After the vacuum suction cup 17 of the assembly trolley picks up the right inner lining segment 3, it moves circumferentially on the assembly trolley, bringing its longitudinal seam connection surface closer to the longitudinal seam connection surface of the capping inner lining segment 2, leaving 10-20cm for adjustment. The vacuum suction cup 17 moves slowly circumferentially, aligning the CT connector with the arc-shaped adjustment boss or arc-shaped groove at the longitudinal seam connection surface of the right inner lining segment 3 near the capping inner lining segment 2 with the CT connector with the arc-shaped groove or arc-shaped adjustment boss at the longitudinal seam connection surface of the capping inner lining segment 2. Simultaneously, observe the alignment of the threaded steel rod 4 extending from the end face of the right inner lining segment 3 with the sleeve 5 at the end face of the previous ring inner lining segment, as well as the alignment of the U-shaped reserved hole on the right inner lining segment 3 with the connector 32 embedded in the inner arc surface of the segment. The vacuum chuck 17 is adjusted slightly along the six degrees of freedom until the threaded steel bar 4 on the end face of the right inner lining block 3 is aligned with the center line of the sleeve 5 on the end face of the previous inner lining block, and the CT connector at the longitudinal seam of the right inner lining block 3 is still aligned with the CT connector at the longitudinal seam of the capping inner lining block 2; then the vacuum chuck 17 drives the right inner lining block 3 to move axially ( Figure 4(As shown by the arrow), connect the CT connector at the longitudinal joint connection surface of the right inner lining block 3 to the CT connector at the longitudinal joint connection surface of the capping inner lining block 2. Simultaneously, fully insert the threaded steel bar 4 of the right inner lining block 3 into the sleeve 5 of the previous inner lining block. Operate the vacuum suction cup 17 for fine adjustment to ensure that the inner arc surface of the right inner lining block 3 in its current position is flush with the inner arc surface of the previous inner lining block. Check that the circumferential joint grout-blocking strip is fully compressed and that the circumferential joint of the right inner lining block 3 is aligned with the circumferential joint of the segment, confirming that the right inner lining block 3 is assembled in place. Simultaneously, connect the protruding steel bar of the arch foot of the right inner lining block 3 to the pre-embedded connectors 32 on both sides of the box culvert to complete the installation of the right inner lining block 3. After the single-ring liner is assembled, the rounding device 19 of the assembly trolley is started. Based on the fine-tuning data of the CT-shaped socket assembly, precise hydraulic jacking is performed to complete the fine-tuning and shaping of the entire ring liner, realizing the coordinated rounding of the CT-shaped socket assembly and the rounding device 19.

[0045] S4. The inner lining is fixed by segmented connection.

[0046] S4.1, such as Figure 10 As shown, after each lining segment is in place, the connecting rod 31 is screwed into the pre-embedded connector 32 inside the segment through the U-shaped reserved hole on the inner arc surface of the lining, ensuring that the length of the connector protruding from the inner arc surface of the lining segment is 15mm.

[0047] S4.2, such as Figure 11 As shown, insert the steel mesh 25 (8mm in diameter, 40mm spacing) into the U-shaped pre-drilled hole, and screw the first steel plate 24 into the appropriate position of the connecting rod 31, ensuring that the first steel plate 24 is located outside the steel mesh 25, and the gap between the first steel plate 24 and the steel mesh 25 is no more than 5mm.

[0048] S4.3, such as Figure 12 As shown, a third steel plate 26 is installed so that it is closely attached to the first steel plate 24, and the third steel plate 26 is firmly welded to the first steel plate 24 by plugging the long strip hole in the third steel plate 26. The short side of the third steel plate 26 is welded and fixed to the fourth steel plate 21 and the fifth steel plate 23.

[0049] S4.4, such as Figure 13 As shown, the second steel plate 27 is installed so that it is in close contact with the third steel plate 26 (without welding).

[0050] S4.5, such as Figure 14 As shown, install the seventh steel plate 29 and the eighth steel plate 28 to seal the bottom of the U-shaped reserved hole in the inner lining, and weld them firmly to the fourth steel plate 21, the fifth steel plate 23, and the sixth steel plate 22; the width of the seventh steel plate 29 and the eighth steel plate 28 needs to be determined according to the orientation of the third steel plate 26 at the construction site.

[0051] S4.6, such as Figure 15As shown, the U-shaped pre-reserved hole circumferential joint of the inner lining is sealed by the ninth steel plate 30, and it is firmly welded to the fourth steel plate 21, the fifth steel plate 23 and the eighth steel plate 28 to complete the connection and fixation of the inner lining sections.

[0052] S5. Treatment of damaged sections of the inner lining.

[0053] S5.1 If any lining section is damaged during construction, it shall be handled immediately according to the “inspection-assessment-solution-repair” process: take photos of the damaged area from multiple angles for archiving, have the on-site engineer or quality inspector determine the damage level, and take corresponding repair or scrapping measures according to the surface, moderate or severe damage type. The repair plan must be approved by the design or engineering section.

[0054] S5.2 The specific process of "inspection-evaluation-solution-repair" is as follows: (1) Check and photograph archive: Take clear photos of the damaged parts from multiple angles as the basis for subsequent evaluation and repair.

[0055] (2) Preliminary assessment: The on-site engineer or quality inspector shall make a preliminary assessment of the severity of the damage. Surface damage includes only edge and corner impacts, partial cracks, loosening, and peeling of the concrete cover, with no exposed reinforcing steel. Moderate damage includes peeling of the concrete cover and exposed reinforcing steel. Severe damage includes large-area cracking and breakage of the concrete, affecting the main stress-bearing parts and assembly joints.

[0056] (3) After on-site assessment, an assessment report is prepared, and a repair plan is determined based on the assessment plan.

[0057] (4) Repair plans are classified according to the location and extent of damage: For damage to the inner arc surface, all loose concrete blocks must be removed until a solid base layer is exposed. The base surface should be polished smooth using diamond blades and coated with a cement-based crystalline waterproof coating for protection. For moderate damage to the inner arc surface, the concrete detachment section should be polished smooth, cleaned with compressed air or water, and the exposed reinforcing bars should be coated with acrylic polyurethane paint for corrosion protection. If large-area cracking or breakage of the inner lining concrete blocks occurs and the damage affects the main load-bearing parts or assembly interfaces, the inner lining block must be scrapped and replaced. If surface or moderate damage occurs on the outer arc surface or connecting surface of the inner lining block, the damaged surface should be cleaned and the grouting material should self-repair during the grouting process. If the damaged part involves CT-shaped socket components, threaded steel rod-sleeve, or connecting rod-connector and other connection structures, the connection structure must be replaced or repaired to ensure that its whole-circle adjustment, elastic adaptation, and angle adjustment functions are normal.

[0058] S6, Error Control.

[0059] During construction, assembly errors are strictly controlled through a triple technical system of "structural self-adjustment + precise equipment control + process error elimination." Specifically, the allowable error in the lining assembly is controlled within 0.5mm. This precision is ensured by real-time fine-tuning of the CT-shaped socket assembly, gap compensation between the threaded steel bar and sleeve, and the six-degree-of-freedom micron-level fine-tuning of the equipment. After every 150m of assembly, a spare ring is activated. The increased adjustment gap and lifting extension stroke of the spare ring are used to eliminate accumulated errors, ensuring that the alignment deviation between the lining and the segment ring is controlled within the range of -70 to +80 mm. At the same time, this error control system is linked in real time with the shield tunneling process scheduling system. The hoisting, transportation, and assembly processes of the lining assembly are staggered with the shield tunneling, segment installation, and material transportation processes. The seamless operation characteristics of the complete set of mechanized equipment enable the coordinated advancement of multiple processes.

[0060] S7. Side ditch foundation pouring and grouting isolation end sealing.

[0061] S7.1. Each 5-ring section is a cycle segment. After the prefabricated lining in the segment is assembled, the side ditch foundation is poured and the grouting is used to seal the end of the partition.

[0062] S7.2 Before pouring the side ditch foundation, the inner steel bars of the left inner lining block 1 and the right inner lining block 3 on both sides of the tunnel shall be lapped and tied with the connecting steel bars of the corner connector of the precast box culvert, and the diagonal steel bars of the side ditch foundation shall be lapped and tied with the adjacent anchor bars. The formwork shall be erected and the cast-in-place side ditch foundation shall be poured, and the end of the inner lining shall not be exposed.

[0063] S7.3 The sealing of the grouting partition ends uses sulfoaluminate ultra-early strength (micro-expansion) cement, tail brush and PE foam strip to ensure that the sealing strength meets the grouting pressure requirements of the grouting layer.

[0064] S8. Grouting behind the wall.

[0065] Before grouting, the shrinkage rate and fluidity of the grout under different mix proportions must be thoroughly tested. The grouting pressure should be verified based on the height of the grouting layer and the fluidity of the grout. Grouting should be carried out from bottom to top in two layers. During grouting, the grouting holes immediately above the layer interfaces should be opened to release air and ensure full grouting. Simultaneously, the grout must fully fill the arc-shaped gaps of the CT-shaped socket assembly, the elastic buffer layer gaps between the threaded steel rod 4 and the sleeve 5, the connection gaps between the connecting rod 31 and the connector 32, and the splicing gaps of multiple steel plates, forming an integral sealed grouting layer to further enhance the structural integrity and deformation resistance.

[0066] Although embodiments of the present invention have been shown and described, these specific embodiments are merely explanations of the invention and are not intended to limit it. The specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. After reading this specification, those skilled in the art may make modifications, substitutions, and variations to the embodiments as needed without departing from the principles and spirit of the invention, but such modifications, substitutions, and variations are protected by patent law as long as they are within the scope of the invention.

Claims

1. A method for installing prefabricated inner linings in shield tunnels, characterized in that, Includes the following steps: Step 1. Design the structure of the inner lining: The inner lining is designed as a structure in which multiple inner lining blocks are connected to each other. The circumferential connection between adjacent inner lining blocks is connected by CT-shaped socket components, and the longitudinal connection between adjacent inner lining blocks is connected by threaded steel bars and sleeves. The CT-shaped socket assembly includes a C-shaped part and a T-shaped part. The socket of the C-shaped part is located on the longitudinal mating surface of the inner lining block. The T-shaped part is provided with an arc-shaped adjusting boss, and the C-shaped part is provided with an arc-shaped groove that cooperates with the arc-shaped adjusting boss. The arc-shaped adjusting boss has a radial fine adjustment of ±5° in the arc-shaped groove to realize the real-time full circle correction of the inner lining block. The end of the threaded steel bar is provided with a guide taper, and the inner wall of the sleeve is provided with an elastic buffer layer; there is a 2mm installation adjustment gap between the threaded steel plate and the sleeve. Step 2. Layout of complete set of installation equipment: Along the tunnel boring direction, a cantilever crane, a lifting feeding trolley and an assembly trolley are set up in sequence. The cantilever crane is equipped with a clamping lifting device, and the assembly trolley is equipped with a vacuum suction cup, a laser positioning sensor and a rounding device. The assembly trolley also includes a support assembly, a work platform, and an assembly robotic arm. The assembly robotic arm is equipped with a vacuum suction cup with a six-degree-of-freedom adjustment function. The vacuum suction cup can reliably grasp the inner lining blocks and adjust the inner lining blocks in any posture in space through the six-degree-of-freedom adjustment function to ensure the precise positioning and installation of the inner lining blocks. The main body of the cantilever crane is an inverted U-shaped frame structure with a hollow lower part, which allows the transport vehicle to approach the lifting and feeding trolley. The cantilever crane is used for lifting and changing the posture of the inner lining sections from the transport vehicle to the lifting and feeding trolley, and can operate flexibly in narrow tunnel spaces. The rounding device is an arc-shaped hydraulic jacking structure. Its jacking end is equipped with an arc-shaped jacking plate with the same curvature as the inner arc surface of the liner. The rounding device is jacked according to the fine-tuning data of the CT-shaped socket assembly. Step 3. Use the installation equipment described in Step 2 to transport and hoist the inner lining segments, and assemble and fix the inner lining segments to the inner arc surface of the tube segment; after every 150m of assembly, activate a spare ring, in which the adjustment gap of the CT-shaped socket assembly is greater than the adjustment gap of the CT-shaped socket assembly in other inner lining rings.

2. The method for installing prefabricated inner lining of a shield tunnel according to claim 1, characterized in that, In step 1, an L-shaped connection notch is provided at the circumferential connection end of two adjacent inner lining blocks.

3. The method for installing prefabricated inner lining of a shield tunnel according to claim 1, characterized in that, In step 1, the outer end face of the inner lining segment is machined with a U-shaped reserved hole. After the inner lining segment is assembled in place, the connecting rod is screwed into the connector on the inner arc surface of the pipe segment through the U-shaped reserved hole. A steel mesh and a multi-layer steel plate assembly are installed outside the connecting rod. The multi-layer steel plate assembly is spliced ​​on site according to the outer arc surface of the inner lining. After being attached to the inner lining segment and the pipe segment, it is welded and fixed to complete the connection between the inner lining segment and the pipe segment.

4. The method for installing prefabricated inner lining of a shield tunnel according to claim 1, characterized in that, In step 3, during the transportation of the inner lining blocks, a tray is placed between two adjacent inner lining blocks. The tray is a horizontal U-shaped structure with lifting clamping holes at both ends and an isolation groove on the bottom surface of the U-shaped structure.

5. The method for installing prefabricated inner lining of a shield tunnel according to claim 1, characterized in that, In step 3, a sealant is used to fill the gap between the arc-shaped groove and the arc-shaped adjusting boss in the CT-shaped socket assembly, thereby fixing and shaping the socket assembly.

6. The method for installing prefabricated inner lining of a shield tunnel according to claim 1, characterized in that, In step 3, after every 5 rings of inner lining are assembled, the side ditch foundation is poured and the grouting is used to seal the end of the partition.

7. The method for installing prefabricated inner lining of a shield tunnel according to claim 1, characterized in that, In step 3, after the inner lining is installed, the grouting layer is constructed layer by layer from bottom to top, and the thickness of the grouting layer is 35 mm.

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