Tunnel cross-fault buffer layer system based on SAP aggregate concrete
By using SAP aggregate concrete beams with uniform cross-sections and a hoisting system in the tunnel buffer layer, the construction complexity and performance instability of traditional tunnel buffer layers have been solved, realizing an efficient, economical, and environmentally friendly tunnel buffer layer system that improves the safety and seismic performance of the tunnel.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-28
- Publication Date
- 2026-03-31
AI Technical Summary
Traditional large-volume foamed concrete has problems in tunnel buffer layer construction, such as unstable bottom bubble performance, easy formwork collapse, high filling cost, complex construction, serious loss of the buffer layer's seismic isolation performance, and drying shrinkage after pouring. It is difficult to guarantee the consistency and reliability of product quality, and it increases the construction difficulty and cycle.
Using SAP aggregate concrete with uniform cross-section beams and a hoisting system, large-diameter spherical superabsorbent resin is distributed in the concrete body as coarse aggregate, combined with components such as lifting rings and wire ropes to form a shock-absorbing buffer layer, thus realizing the prefabricated installation of the cross-fault tunnel.
It significantly improves the seismic isolation and damping effect of the buffer layer, simplifies the construction process, reduces construction difficulty and cost, ensures the performance consistency and reliability of the buffer layer, and improves the safety and seismic toughness of the tunnel.
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Figure CN224064353U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of seismic design and construction technology in tunnel engineering, and more specifically, to a tunnel cross-fault buffer layer system based on SAP aggregate concrete. Background Technology
[0002] With the acceleration of urbanization and the development of transportation infrastructure worldwide, tunnels, as vital channels connecting different geographical regions, play an indispensable role in modern transportation networks. However, tunnels face significant challenges when traversing areas with complex geological structures, especially seismically active zones. While traditional large-volume foamed concrete is widely used in the construction of tunnel buffer layers, it suffers from problems during large-scale pouring, including unstable bottom air bubble performance, easy formwork collapse, high filling costs, complex construction procedures, severe loss of the buffer layer's seismic isolation performance, and post-pouring drying shrinkage of the filling material. These issues seriously affect the quality and seismic toughness of the k-span fault tunnel project.
[0003] Furthermore, traditional construction methods often rely on on-site pouring or filling PE pipes with foamed concrete to allow for a 7-day curing period. The concrete is then processed at a location within the tunnel to reach the required strength before being transported to the construction site and installed as a whole within the damping layer. This not only increases the difficulty and time required for construction but also makes it difficult to guarantee the consistency and reliability of product quality. Therefore, developing a highly efficient, economical, environmentally friendly tunnel buffer layer system with excellent seismic performance is of great significance for improving the safety and seismic resilience of cross-fault tunnel projects. Utility Model Content
[0004] In view of the deficiencies in the prior art, the purpose of this application is to provide a tunnel cross-fault buffer layer system based on SAP aggregate concrete.
[0005] One aspect of this application provides a tunnel cross-fault buffer layer system based on SAP aggregate concrete, comprising: a beam with uniform cross-section and a hoisting system, wherein:
[0006] The beam with uniform cross-section is composed of a frame and a concrete body. The concrete body contains coarse aggregate, which is spherical superabsorbent resin with a particle size of 20mm-60mm.
[0007] The frame includes ribbed longitudinal steel bars and stirrups, and the ribbed longitudinal steel bars are fixedly connected to the stirrups to form the frame of the beam with equal cross-section;
[0008] The hoisting system installs the equal-section beam between the primary and secondary linings of the tunnel, forming a vibration-damping buffer layer.
[0009] Furthermore, symmetrical lifting rings are also provided on the stirrups.
[0010] Furthermore, the lifting rings are in two sets, located at both ends of the beam with uniform cross-section.
[0011] Furthermore, the distance between the lifting ring and both ends of the uniform cross-section beam is 0.15 to 0.25 times the length of the uniform cross-section beam.
[0012] Furthermore, the particle size of the spherical superabsorbent resin is 30mm to 50mm.
[0013] Furthermore, the hoisting system includes:
[0014] Pull rings are installed in the tunnel's support structure;
[0015] A steel wire rope, passing through the pull ring and the lifting ring, is used to lift the beam with the same cross-section.
[0016] Furthermore, the hoisting system also includes a perforated clamping plate and a wire rope shackle;
[0017] The perforated clamp and the wire rope clamp are installed at the junction of the excavated section and the non-excavated section of the tunnel. The wire rope is connected to the perforated clamp and the wire rope clamp in sequence to form a series structure. The perforated clamp is used to restrict the position of the wire rope; the wire rope clamp is used to adjust the length of the wire rope.
[0018] Furthermore, the perforated plate has holes, and the wire rope retainer has a U-shaped groove. The wire rope first passes through the holes of the perforated plate, then bends and is placed into the U-shaped groove of the wire rope retainer, and the wire rope is secured with bolts to complete the limiting connection. The bolts can be loosened to adjust the length of the wire rope.
[0019] Furthermore, the perforated clamp and the wire rope clamp are in two sets, which are symmetrically arranged at the junction of the widened section and the non-widened section at both ends of the tunnel.
[0020] Furthermore, the pull ring has two sets, symmetrically arranged relative to the centerline of the tunnel's support structure.
[0021] Compared with the prior art, this application has at least one of the following beneficial effects:
[0022] The tunnel cross-fault buffer layer system provided in this application has coarse aggregate distributed in the concrete main body of the uniform cross-section beam, which improves the compressive strength and toughness of the uniform cross-section beam and significantly enhances its adaptive deformation capacity, thereby effectively improving the vibration reduction and isolation effect of the buffer layer.
[0023] The tunnel cross-fault buffer layer system provided in this application achieves the assembly and installation of the buffer layer in the widened section of the cross-fault tunnel through the structural cooperation of equal cross-section beams and hoisting system. While ensuring the consistency and reliability of the buffer layer's seismic isolation performance, this integrated installation scheme simplifies the construction process, reduces construction difficulty, and significantly reduces the construction period and cost, while ensuring the safety and seismic toughness of the tunnel project. Attached Figure Description
[0024] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:
[0025] Figure 1 This is a schematic diagram of the overall structure of a tunnel cross-fault buffer layer system based on SAP aggregate concrete according to an embodiment of this application.
[0026] Figure 2 This is a cross-sectional view of a beam with a uniform cross-section in one embodiment of this application.
[0027] Figure 3 This is a schematic diagram of the hoisting system in one embodiment of this application.
[0028] In the diagram: 100, beam with uniform cross-section; 101, coarse aggregate; 102, ribbed longitudinal reinforcement; 103, stirrups; 104, lifting ring; 200, lifting system; 201, wire rope; 202, perforated clamp; 203, wire rope shackle; 204, pull ring. Detailed Implementation
[0029] The present application will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present application, but do not limit the present application in any way. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present application. These all fall within the protection scope of the present application.
[0030] Reference Figure 1 As shown, this application discloses an embodiment of a tunnel cross-fault buffer layer system based on SAP aggregate concrete, comprising: a constant cross-section beam 100 and a hoisting system 200; wherein: the constant cross-section beam 101 is composed of a frame and a concrete body, the concrete body containing coarse aggregate, which is spherical superabsorbent resin with a particle size of 20mm-60mm; the frame includes: ribbed longitudinal steel bars 102, stirrups 103, and lifting rings 104; the ribbed longitudinal steel bars 102 and stirrups 103 are fixedly connected to form the frame of the constant cross-section beam 100; the hoisting system 200 installs the constant cross-section beam 101 between the tunnel primary lining and secondary lining to form a seismic isolation buffer layer.
[0031] This application utilizes large-diameter spherical superabsorbent polymer (SAP) as coarse aggregate 101 in a uniform cross-section beam 100 and a hoisting system 200, which improves the compressive strength and toughness of the uniform cross-section beam and significantly enhances its adaptive deformation capacity, thereby effectively improving the seismic isolation effect of the buffer layer. Ribbed longitudinal steel bars 102 resist the bending moment and shear force generated by the self-weight of the uniform cross-section beam 100, preventing damage to the beam. By setting lifting rings 104 and configuring closed stirrups 103 below them, the peak values of positive and negative bending moments of the uniform cross-section beam 100 are ensured to be equal during hoisting, guaranteeing structural safety and stability. The hoisting system 200 enables the assembly and installation of the buffer layer in the widened section of the cross-fault tunnel, ensuring the consistency and reliability of the buffer layer's seismic isolation performance, simplifying the construction process, reducing construction difficulty, and significantly shortening the construction period and cost, while simultaneously ensuring the safety and seismic toughness of the tunnel project.
[0032] In some specific embodiments, hoisting rings 104 are also symmetrically arranged on the stirrups 103.
[0033] Specifically, there are two sets of lifting rings 104, located at both ends of the beam 100 with uniform cross-section.
[0034] More specifically, the distance between the lifting ring 104 and the two ends of the uniform cross-section beam 100 is 0.15 to 0.25 times the length of the uniform cross-section beam 100.
[0035] Specifically, refer to Figure 2 As shown, there are two sets of lifting rings 104, located at both ends of the uniform cross-section beam 100, and the distance from the ends of the uniform cross-section beam 100 is 0.20 times the length of the uniform cross-section beam 100.
[0036] Specifically, a uniform cross-section beam 100 is constructed using large-diameter spherical superabsorbent polymer (SAP) as coarse aggregate 101, along with a specially designed lifting and hoisting system 200. The uniform cross-section beam 100 utilizes the unique physical properties of SAP aggregate, which not only improves the compressive strength and toughness of the material but also significantly enhances its adaptive deformation capacity, thereby effectively improving the vibration reduction and isolation effect of the buffer layer. Two lifting rings 104 are installed at a distance of approximately 0.20 times the beam length from both ends of the uniform cross-section beam 100, and closed stirrups 103 are configured below the lifting rings 104 to ensure that the peak values of positive and negative bending moments of the beam are equal during hoisting, thus ensuring structural safety and stability.
[0037] The design of the lifting ring 104 and the closed stirrup 103 not only takes into account the mechanical performance requirements during the lifting process, but also protects the overall structural integrity of the equal cross-section beam 100, thus avoiding the problem of local stress concentration that may be caused by the lifting operation.
[0038] In some specific embodiments, the particle size of the large-particle-size spherical superabsorbent resin can be 30mm to 50mm.
[0039] By adding coarse aggregate to the concrete matrix, the amount of cement used can be reduced, thus reducing costs.
[0040] In some possible embodiments, the hoisting system 200 includes: a pull ring 204 disposed in the tunnel support structure; and a wire rope 201 passing through the pull ring 204 and the hoisting ring 104 for installing the uniform cross-section beam 100 between the tunnel primary lining and secondary lining to form a vibration damping buffer layer.
[0041] Specifically, during use, the pull ring 204 is pre-embedded in the initial support structure of the tunnel, and the lifting ring 104 on the equal section beam 100 is connected to the pull ring 204 pre-embedded in the initial support structure of the tunnel by the steel wire rope 201, so as to ensure that the equal section beam 100 is installed in place.
[0042] Reference Figure 3 As shown, in some specific embodiments, the hoisting system 200 also includes a perforated clamping plate 202 and a wire rope clamping ring 203. The perforated clamping plate 202 and the wire rope clamping ring 203 are set at the junction of the excavated section and the non-excavated section. The wire rope 201 is connected to the perforated clamping plate 202 and the wire rope clamping ring 203 in sequence to form a series structure. The perforated clamping plate 202 is used to limit the position of the wire rope 201, and the wire rope clamping ring 203 is used to adjust the length of the wire rope 201.
[0043] This application establishes a stable connection point between the perforated clamp plate 202 and the wire rope clamp 203, ensuring that the entire lifting and hoisting system 200 remains stable and reliable during operation, and can successfully complete the assembly task even in complex underground environments.
[0044] In some specific embodiments, the perforated plate 202 has holes, and the wire rope retainer 203 has a U-shaped groove. The wire rope 201 first passes through the holes of the perforated plate 202, then bends and puts into the U-shaped groove of the wire rope retainer 203, and the wire rope 201 is fastened with bolts to complete the limiting connection. The bolts can be loosened to adjust the length of the wire rope 201.
[0045] Specifically, there are two sets of pull rings 204, symmetrically arranged relative to the centerline of the tunnel support structure. There are also two sets of perforated clamping plates 202 and wire rope clamping rings 203, symmetrically arranged at the junctions of the widened and non-widened sections at both ends of the tunnel.
[0046] The hoisting system 200 can be adapted to beams 100 of different sizes and shapes with uniform cross sections. By adjusting the length of the wire rope 201 and the position of other components, it can meet the actual engineering requirements and has high flexibility and adaptability.
[0047] The hoisting system 200 uses a perforated clamping plate 202 and a wire rope clamping ring 203 at the junction of the excavated and non-excavated sections. The wire rope 201 passes through the perforated clamping plate 202 and the wire rope clamping ring 203 in sequence to form a series structure, which can limit the position of the wire rope 201. At the same time, the wire rope clamping ring 203 can adjust the length of the wire rope 201. The wire rope 201 first passes through the hole of the perforated clamping plate 202, and then bends and puts into the U-shaped groove of the wire rope clamping ring 203. The clamping ring is tightened by bolts to complete the limiting connection with the wire rope 201. The connection point can release the wire rope 201 by loosening the clamping ring bolts, and the hole position or clamping ring position can be reselected during adjustment to adapt to the requirements, ensuring the stable limiting and flexible adjustment of the wire rope 201 during the installation of the uniform cross-section beam 100.
[0048] It should be noted that the perforated clamp 202 and the wire rope clamp 203 are pre-embedded and fixed in advance at the junction of the excavated section and the non-excavated section for fixation (e.g., by pouring, welding, etc.). The bolt tightening of the wire rope clamp 203 is to adjust the length of the wire rope 201. The perforated clamp 202 restricts the position of the wire rope 201 through the holes to prevent displacement.
[0049] This application is applicable to various types of tunnel engineering projects, especially those located in seismically active areas or where special attention needs to be paid to seismic performance. It can significantly improve the safety protection level of tunnels. Through an integrated installation scheme, it realizes the factory prefabrication and on-site assembly of the buffer layer in the widened section of cross-fault tunnels, ensuring the consistency and reliability of the buffer layer's seismic isolation performance. This greatly simplifies the construction process, reduces construction difficulty, and significantly shortens the construction period and cost. The presence of coarse aggregate in the concrete reduces concrete costs, thus achieving an efficient and economical solution. Similarly, this application fully considers environmental protection requirements during the design phase, selecting environmentally friendly coarse aggregates and technologies to minimize the impact on the natural environment. Every step follows relevant standards and specifications to ensure the high performance and long service life of the final product.
[0050] In this application, the construction process includes (1) concrete preparation, (2) factory prefabrication, (3) assembly of lifting and fixing system, (4) on-site installation and (5) construction management and maintenance.
[0051] Specifically, (1) Concrete preparation:
[0052] According to the requirements of the project, prepare high-strength concrete with appropriate fluidity and hardening properties, and add coarse aggregate to the concrete.
[0053] Coarse aggregate can be selected from spherical superabsorbent polymer (SAP) particles with a particle size of 20mm-60mm. SAP possesses sufficient strength and water absorption expansion characteristics to enhance the compressive strength, toughness, and adaptive deformation capacity of concrete. The specific distribution ratio of coarse aggregate in concrete can be determined according to the requirements of the actual project. The more spherical superabsorbent polymer (SAP) distributed in the concrete, the higher the compressive strength, toughness, and adaptive deformation capacity of the beam with uniform cross-section, and the better the vibration reduction and isolation effect of the buffer layer. Conversely, if less spherical superabsorbent polymer (SAP) is distributed, the aforementioned compressive strength, toughness, and adaptive deformation capacity will be lower, and the vibration reduction and isolation effect of the buffer layer will be correspondingly reduced, but still better than the effect of traditional concrete without distributed spherical superabsorbent polymer (SAP).
[0054] (2) Factory prefabrication:
[0055] Mold preparation: Customize special molds according to the design drawings to ensure the dimensional accuracy of each component.
[0056] Reinforcement configuration: Two ribbed longitudinal steel bars 102 are provided at the top and bottom edges of the beam to resist the bending moment and shear force generated by its own weight; two lifting rings 104 are set at a distance of about 0.20 times the beam length from both ends of the beam, and closed stirrups 103 are provided below the lifting rings 104 to ensure that the peak values of positive and negative bending moments of the beam are equal during hoisting.
[0057] Pouring and curing: Concrete with added coarse aggregate is poured into the mold to form beam 101 with uniform cross section, and then standard curing is carried out until the design strength is reached.
[0058] (3) Assembly of the hoisting system:
[0059] Installation of embedded parts: Pre-embedded beams 100 with coarse aggregate 101 and pull rings 204 in the initial lining of the tunnel widening section, as well as perforated clamping plates 202 pre-embedded at the junction of the widening section and the non-widening section.
[0060] Steel wire rope 201 connection: The lifting ring 104 on the concrete beam is connected to the pull ring 204 pre-embedded in the initial support structure of the tunnel by steel wire rope 201 to ensure that the beam is installed in place.
[0061] Use of wire rope shackle 203: Wire rope shackle 203 is used to achieve stable installation of beams and ensure that the entire lifting and hoisting fixing system remains stable and reliable in operation.
[0062] (4) On-site installation:
[0063] Transportation and positioning: The precast concrete beams are transported to the construction site and positioned according to the design requirements.
[0064] Lifting operation: Using equipment such as cranes, the concrete beams are lifted and installed through a lifting system.
[0065] Quality Inspection: After installation, a comprehensive quality inspection will be conducted to ensure that all components are tightly connected and there are no loose parts.
[0066] (5) Construction Management and Maintenance
[0067] Construction progress control: Develop detailed construction plans to ensure that each process is carried out in an orderly manner according to the plan.
[0068] Safety measures implementation: Strictly abide by construction safety regulations, take necessary protective measures, and ensure the safety of construction personnel.
[0069] Post-construction maintenance: Regularly inspect and maintain the completed buffer layer, promptly address any issues discovered, and ensure its long-term stable operation.
[0070] The embodiments described above provide a tunnel buffer layer system that is efficient, economical, environmentally friendly, and has excellent seismic performance, significantly improving the safety and seismic resilience of cross-fault tunnel projects.
[0071] The specific embodiments of this application have been described above. It should be understood that this application is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the substantive content of this application. The above-described preferred features can be used in any combination without conflict.
Claims
1. A SAP aggregate concrete based tunnel fault-crossing cushion system, characterized in that, The utility model relates to a kind of equal cross-section beam and hoisting system, wherein: The equal cross-section beam is composed of frame and concrete body, and the coarse aggregate with particle size of 20mm-60mm is distributed in the concrete body, and the coarse aggregate is spherical superabsorbent resin; The frame includes ribbed longitudinal reinforcement and stirrup, and the ribbed longitudinal reinforcement is fixedly connected with the stirrup to form the frame of the equal cross-section beam; The hoisting system is installed between the tunnel primary lining and secondary lining to form a shock-absorbing buffer layer. Symmetrical lifting rings are arranged on the stirrup.
2. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 1, characterized in that, The lifting rings are located at two ends of the equal cross-section beam.
3. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 2, characterized in that, The length of the lifting rings from the two ends of the equal cross-section beam is 0.15-0.25 times the length of the equal cross-section beam.
4. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 3, characterized in that, The particle size of the spherical superabsorbent resin is 30mm-50mm.
5. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 1, characterized in that, The hoisting system includes:
6. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 2, characterized in that, A pull ring is arranged in the supporting structure of the tunnel. A steel wire rope passes through the pull ring and the lifting ring to hoist the equal cross-section beam. The hoisting system further includes a hole card plate and a steel wire rope clasp.
7. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 6, characterized in that, The hole card plate and the steel wire rope clasp are arranged at the joint of the expanded section and the non-expanded section of the tunnel, and the steel wire rope is connected in series with the hole card plate and the steel wire rope clasp. The hole card plate is used to limit the position of the steel wire rope, and the steel wire rope clasp is used to adjust the length of the steel wire rope.
8. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 7, characterized in that, The hole card plate is provided with a hole, and the steel wire rope clasp is provided with a U-shaped groove.
9. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 7, characterized in that, The steel wire rope is first threaded through the hole of the hole card plate, then bent and placed in the U-shaped groove of the steel wire rope clasp, and finally fastened with a bolt to complete the limiting connection.
10. A SAP aggregate concrete based tunnel fault-crossing cushion system according to claim 6, characterized in that, The bolt can be loosened to adjust the length of the steel wire rope. The hole card plate and the steel wire rope clasp have two sets, which are symmetrically arranged at the joint of the expanded section and the non-expanded section at two ends of the tunnel. The pull ring has two sets, which are symmetrically arranged relative to the center line of the supporting structure of the tunnel.