Shield damaged segment steel ring repairing and reinforcing structure
By applying steel ring lining, composite anchoring system and anti-corrosion and fire-resistant coating, the problems of insufficient rigidity and poor durability of shield tunnel segments are solved, realizing efficient and safe repair of shield tunnels, which is suitable for complex urban conditions.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 广州市盾建建设有限公司
- Filing Date
- 2025-06-30
- Publication Date
- 2026-05-15
AI Technical Summary
Existing methods for repairing shield tunnel segments cannot effectively improve stiffness, have weak interfacial bonding and poor durability, and involve high construction risks or costs, making it difficult to meet the requirements for high safety and construction period.
A composite anchoring system is formed by using a steel ring liner, mechanical anchors for damaged segments, and rear-expanded bolts. Combined with a rigid epoxy resin filling layer, a continuous and sealed bonding interface is formed. The surface of the steel ring liner is coated with an anti-corrosion and fire-resistant coating, and a hydraulic positioning tool is used for rapid installation.
It significantly enhances the circumferential stiffness of the tunnel segments, achieves uniform stress transfer across the entire interface, improves durability and construction safety, shortens the construction period, and reduces the impact on the surrounding environment.
Smart Images
Figure CN224244900U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of shield tunnel engineering technology, and more specifically to a steel ring repair and reinforcement structure for damaged shield tunnel segments. Background Technology
[0002] As the main barrier in a single-layer lining structure, the safety of shield tunnel segments directly affects the overall stability of the tunnel. Currently, the main repair methods for damaged segments include:
[0003] 1. Filling method: Cement mortar or epoxy resin is used to fill local damage, but this is only suitable for minor damage and cannot solve structural safety problems.
[0004] 2. Cut-and-cover method: This method requires reinforcement and repair of the surrounding strata, which carries high construction risks and can easily have adverse effects on adjacent structures.
[0005] 3. Open-cut method: Although it is convenient to construct and the quality is controllable, it has a long construction period, high cost, and a significant impact on urban traffic.
[0006] The above methods have the following technical drawbacks: traditional filling methods cannot improve the overall rigidity of the tunnel segments and cannot meet high safety requirements; the underground excavation method has high construction risks and the reinforcement process is complex; the open excavation method is not economical and cannot meet the construction period requirements. Utility Model Content
[0007] The purpose of this utility model is to solve the technical problems of insufficient reinforcement stiffness, weak interface bonding and poor durability of existing repair methods. This utility model provides a steel ring repair and reinforcement structure for damaged shield tunnel segments.
[0008] The technical solution adopted in this utility model is as follows: A steel ring repair and reinforcement structure for damaged tunnel segments, comprising:
[0009] The steel ring liner is formed by assembling multiple arc-shaped steel plates and is attached to the inner surface of the damaged segment;
[0010] Anchoring components, including mechanical anchors that penetrate the steel ring liner and the damaged segment, and rear-expanded bolts;
[0011] A rigid epoxy resin filler layer is used to fill the gap between the steel ring liner and the damaged segment.
[0012] Preferably, the width of the steel plate in the top area of the steel ring liner is greater than the width of the steel plates in other areas, and the joints of the steel plates are chamfered.
[0013] Preferably, the mechanical anchors are arranged in a quincunx pattern, and the rear-expanded bolts are spaced apart along the circumferential and longitudinal directions of the inner lining of the steel ring.
[0014] Preferably, the rigid epoxy resin filler layer is injected under pressure through pre-embedded grouting holes to form a continuous and sealed bonding interface.
[0015] Preferably, the inner surface of the steel ring is coated with an anti-corrosion coating and a fire-resistant coating in sequence.
[0016] Preferably, it also includes a hydraulic positioning fixture for adjusting the position of the inner liner of the steel ring, the fixture being detachably connected to the inner liner of the steel ring.
[0017] Preferably, the pretreatment of the damaged segments includes: repairing the cracks by graded grouting; welding steel mesh to the damaged area and filling it with resin; and elastically filling the segment joints and reserving grouting channels.
[0018] Preferably, the butt joint edges of the arc-shaped steel plates of the inner lining of the steel ring are provided with a tenon and mortise interlocking structure, an elastic sealing gasket is laid between the tenon and mortise joint surfaces of adjacent steel plates, and the plates are laterally locked by rear-expanded bottom bolts.
[0019] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:
[0020] This invention forms a rigid support frame through a steel ring liner and a tenon-and-mortise splicing structure, which greatly enhances the circumferential stiffness of the pipe segments and significantly improves the structural performance.
[0021] The plum blossom-shaped mechanical anchor bolts and the longitudinally spaced rear-expanded bottom bolts form a composite anchoring system. Combined with the pressure-injected rigid epoxy resin filling layer, it achieves tight bonding between the steel ring liner and the entire interface of the segment, ensuring that the interface bonding stress meets the standard, effectively transferring loads and coordinating deformation, and ensuring reliable interface coordinating stress.
[0022] The anti-corrosion and fire-resistant coating system on the inner surface of the steel ring can resist humid and corrosive environments and fire risks, significantly extending the service life of the structure; the pretreatment process for damaged segments is designed for graded repair of cracks, damage, and joints, improving the structural durability from the base layer level, and comprehensively enhancing durability.
[0023] Using hydraulic positioning fixtures in conjunction with forklifts avoids the risks of manual operation and shortens the construction period compared to traditional methods. It does not require large-area ground reinforcement or road closures, has little impact on the surrounding environment, and is suitable for rapid repair in complex urban conditions, making construction efficient, safe and convenient. Attached Figure Description
[0024] This utility model will be described by way of example and with reference to the accompanying drawings, wherein:
[0025] Figure 1 This is a schematic diagram of the structure of this utility model;
[0026] Figure 2 This is a schematic diagram of the cross-sectional structure of this utility model (AA).
[0027] Figure 3 This is a schematic diagram of the BB cross-sectional structure of this utility model;
[0028] Figure 4 This is a schematic diagram of the planar unfolded structure of this utility model;
[0029] The markings in the diagram are: 1-steel ring liner, 11-steel plate in the top area, 12-steel plate in other areas, 2-damaged segment, 3-rigid epoxy resin filler layer, 4-rear expansion bolt, 5-mechanical anchor bolt, 6-pre-embedded grouting hole, 7-bolt hole. Detailed Implementation
[0030] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can typically be arranged and designed in various different configurations.
[0031] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0032] In one embodiment of this utility model, such as Figure 1-4 As shown, this embodiment provides a steel ring repair and reinforcement structure for damaged tunnel segments, including:
[0033] The steel ring liner 1 is formed by assembling multiple arc-shaped steel plates and is attached to the inner surface of the damaged segment 2;
[0034] Anchoring components include mechanical anchors 5 that penetrate the inner liner of the steel ring 1 and the damaged segment 2, and rear-expanded bolts 4;
[0035] A rigid epoxy resin filler layer 3 fills the gap between the steel ring liner 1 and the damaged segment 2.
[0036] Specifically, the core components and technical features include: The steel ring liner 1 is assembled from multiple arc-shaped steel plates, precisely fitting the inner surface of the damaged segment 2 to form a circumferential support frame. The width of the top area steel plate 11 is greater than that of the other parts of the steel plate 12 (e.g., the width of the top 120° area is 1.4m, while the width of the other areas is 0.9m), which increases the cross-sectional area of the key stress area and improves the deformation resistance of the top. The joints of each steel plate are chamfered (e.g., triangular chamfers) to reduce stress concentration and enhance the structural continuity of the splicing parts. The butt joint edges of each arc-shaped steel plate are equipped with a tenon and mortise interlocking structure, and a 2mm thick elastic sealing gasket such as butyl rubber is laid between the tenon and mortise joint surfaces of adjacent steel plates. It is laterally locked by the rear-expanded bottom bolts 4, which not only enhances the assembly rigidity but also improves the interface sealing performance and prevents groundwater leakage. The reinforcement range is determined based on the structural mechanics simulation model of the tunnel segment (such as the ANSYS shell-rigid beam-spring model). Through three-dimensional structural additional internal force analysis and deformation calculation, the number of tunnel segments and the area to be reinforced are accurately located to ensure that the reinforcement scheme matches the actual stress requirements.
[0037] The anchoring assembly includes mechanical anchors 5 penetrating the steel ring liner 1 and the damaged segment 2, and rear-expanded bolts 4. The mechanical anchors 5 are distributed in a staggered pattern (300mm spacing) to uniformly transmit the interface shear force; the rear-expanded bolts 4 are spaced apart along the circumferential (400mm spacing) and longitudinal (500mm spacing) directions of the steel ring liner 1, with a drilling depth ≥100mm, penetrating 150mm into the segment matrix to form a three-dimensional anchoring structure, ensuring a reliable connection between the steel ring liner 1 and the damaged segment 2 and preventing detachment.
[0038] The rigid epoxy resin filling layer 3 is injected with rigid epoxy resin (compressive strength ≥60MPa) through the pre-embedded grouting hole 6 at a pressure of 0.8MPa, filling the 5-8mm gap between the steel ring liner 1 and the damaged segment 2, forming a continuous and sealed bonding interface, eliminating interface voids, improving the cooperative stress-bearing performance of the steel ring liner 1 and the damaged segment 2, and realizing uniform stress transfer across the entire interface.
[0039] The surface of the auxiliary structural steel ring liner 1 is sequentially coated with an anti-corrosion coating (such as an 80μm thick epoxy zinc-rich primer + a 100μm thick polysiloxane topcoat) and a fire-resistant coating (thick steel structure fireproof coating, fire resistance limit of 2 hours), significantly improving structural durability in the humid and fire-prone environment of tunnels. Equipped with hydraulic positioning fixtures, detachably connected to the steel ring liner 1, and using forklifts for transportation and positioning, rapid adjustment of the steel ring liner 1 is achieved (e.g., vertical and horizontal accuracy control of ±2mm), ensuring uniform gap with the inner surface of the tunnel segments and improving construction efficiency and installation accuracy.
[0040] The pretreatment of damaged segment 2 employed a graded grouting repair technique. Depending on the crack width (<0.2mm, 0.2-0.4mm, >0.4mm), epoxy mortar was used for covering, EAA-modified epoxy grout was injected under pneumatic pressure, and epoxy grout was injected through a grouting pipe across the crack, ensuring effective repair of cracks of different sizes. After cleaning the concrete spalled area, a Φ6@100mm steel mesh was welded (fixed to the segment's reinforcing steel), and then filled with C50 resin concrete or epoxy resin was piled up to restore the segment's matrix strength. The circumferential and longitudinal joints of damaged segment 2 were caulked with elastic epoxy mortar (mixture ratio A:B = 4:1), with a φ20mm grouting channel reserved to balance sealing performance and subsequent maintenance needs.
[0041] In another embodiment of this utility model, the width of the steel plate 11 in the top area of the inner lining 1 of the steel ring is greater than the width of the steel plate 12 in other parts, and the joints of the steel plates are chamfered.
[0042] In another embodiment of this utility model, the mechanical anchor bolts 5 are distributed in a quincunx pattern, and the rear-expanded bolts 4 are spaced apart along the circumferential and longitudinal directions of the inner lining of the steel ring 1.
[0043] In another embodiment of this utility model, the rigid epoxy resin filling layer 3 is injected under pressure through the pre-embedded grouting hole 6 to form a continuous and sealed bonding interface.
[0044] In another embodiment of this utility model, the surface of the steel ring liner 1 is sequentially coated with an anti-corrosion coating and a fire-resistant coating.
[0045] In another embodiment of this utility model, a hydraulic positioning fixture for adjusting the position of the inner steel ring liner 1 is also included. The fixture is detachably connected to the inner steel ring liner 1. The inner steel ring liner 1 is installed using the fixture equipment and with the assistance of a forklift. Utilizing the flexibility and lifting capabilities of the forklift, workers manually assist the forklift in installing the inner steel ring liner 1 onto the work surface, followed by the positioning and installation using the fixture equipment. Compared to the traditional method of manually pulling the steel ring pieces using a hoist, this significantly saves time and improves the safety of the assembly operation.
[0046] In another embodiment of this utility model, the pretreatment of the damaged segment 2 includes: repairing the cracks by graded grouting; welding steel mesh to the damaged area and filling it with resin; elastically filling the segment joints and reserving grouting channels.
[0047] The reinforcement range of the steel ring lining 1 is determined based on the mechanical simulation model of the tunnel segment structure. Specifically, the finite element method is used, employing the shell-rigid beam-spring model in ANSYS software for calculation and analysis, establishing a single-ring lining structure for the shield tunnel, and using the forced displacement method to analyze the additional internal forces and deformations of the three-dimensional structure after longitudinal deformation of the shield tunnel. The segment structure uses layered shell elements to simulate the actual damage to concrete and steel reinforcement materials, clarifying the number of rings requiring repair or reinforcement measures. For lining rings rated C for safety and usability, steel rings are used to reinforce the entire tunnel structure. The reinforcement structure calculation is carried out using ANSYS, and the calculation model includes a shell-rigid beam-spring model considering segment joints, an inner lining steel plate model, and interlayer interface bonding, ensuring that the safety factor (R / S) and segment crack width of the reinforced lining structure meet the requirements. For B-level damaged segments, the base surface is cleaned and repaired with epoxy mortar to the original segment thickness. This structure significantly improves the circumferential stiffness of the tunnel segments, and the safety factor has increased from 0.913 to 1.164 according to finite element analysis. It achieves coordinated stress distribution across the entire interface, enhances durability, and makes construction efficient and safe. It is suitable for rapid repair of tunnel segments under complex working conditions, and significantly shortens the construction period.
[0048] In another embodiment of this utility model, the butt joint edges of each arc-shaped steel plate of the inner lining 1 of the steel ring are provided with a tenon and mortise interlocking structure, an elastic sealing gasket is laid between the tenon and mortise joint surfaces of adjacent steel plates, and is laterally locked by the rear expansion bolt 4.
[0049] The construction process of this utility model is as follows: damage assessment → graded repair of cracks → welding of damaged steel mesh → elastic filling of joints → positioning of steel ring fixtures → anchor bolt fixing → pressure grouting → surface protection → real-time monitoring → acceptance and delivery; the specific steps are as follows:
[0050] 1. Damage assessment and pretreatment
[0051] Damage detection: The width of the segment crack (maximum 0.6 mm), the damaged area (exposed reinforcement area 0.5 m²), and the location of joint leakage are determined by three-dimensional laser scanning and ultrasonic testing.
[0052] Crack treatment: For cracks >0.4mm, grouting pipes are installed across the crack and epoxy grout is injected (pressure 0.5MPa); for cracks 0.2-0.4mm, EAA modified epoxy grout is injected under air pressure; for cracks <0.2mm, epoxy putty is applied after grinding.
[0053] Damage Repair: Clean the exposed rebar area, weld Φ6 rebar rods (150mm spacing, staggered pattern), lay and weld Φ6@100mm rebar mesh, and fill with C50 resin concrete. Joint Treatment: Embed water-swellable rubber strips, reserve grouting channels, and use elastic epoxy mortar for joint sealing.
[0054] 2. Machining and Installation of Steel Ring Liner 1
[0055] Customized steel plates: The top 120° area uses a 1.4m wide and 20mm thick curved steel plate, while the remaining areas use 0.9m wide steel plates. The edges are prefabricated with mortise and tenon structures, and the factory completes rust removal and anti-corrosion primer spraying.
[0056] Positioning and installation: Use a forklift to transport the steel ring to the work surface, adjust its position using a hydraulic positioning fixture to ensure a gap of 5-8mm between it and the inner surface of the segment. After fixing the support leg, drill holes (22mm in diameter and 150mm in depth), install the bottom expansion bolts 4 and mechanical anchor bolts 5, and tighten them.
[0057] 3. Filling and Protection Construction
[0058] Rigid epoxy resin injection: Pressure grouting is performed through the pre-embedded grouting hole 6 until grout overflows from the adjacent hole, and curing is carried out for 24 hours to ensure a firm bond.
[0059] Surface treatment: After the weld flaw detection is qualified, polyurea anti-corrosion topcoat and thick fireproof coating are sprayed on site to form a complete protective layer.
[0060] 4. Monitoring and Acceptance
[0061] Deformation monitoring: Leica TS16 total station was used to monitor the crown settlement, horizontal displacement and convergence deformation in real time. Under subsequent service conditions, the top and bottom convergence deformation of the reinforced structure was between 4.803-5.183 mm and the waist convergence deformation was between 1.661-1.797 mm. All data met the specifications.
[0062] Durability acceptance: The anti-corrosion coating life is verified to be ≥30 years through salt spray test, and the fire resistance test meets the 2h fire resistance limit requirement.
[0063] The above are merely preferred embodiments of this utility model and do not limit the patent scope of this utility model. Any equivalent structural transformations made based on the concept of this utility model and the contents of the specification and drawings of this utility model, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this utility model.
Claims
1. A steel ring repair and reinforcement structure for damaged tunnel segments of a shield tunnel, characterized in that, include: The steel ring liner (1) is formed by assembling multiple arc-shaped steel plates and is attached to the inner surface of the damaged segment (2); The anchoring assembly includes mechanical anchors (5) that penetrate the steel ring liner (1) and the damaged segment (2) and rear-expanded bolts (4); A rigid epoxy resin filler layer (3) is used to fill the gap between the steel ring liner (1) and the damaged segment (2).
2. The repair and reinforcement structure according to claim 1, characterized in that, The width of the steel plate (11) in the top area of the inner lining (1) of the steel ring is greater than the width of the steel plate (12) in other parts, and the joints of the steel plates are chamfered.
3. The repair and reinforcement structure according to claim 1, characterized in that, The mechanical anchors (5) are distributed in a quincunx pattern, and the rear expansion bolts (4) are spaced apart along the circumferential and longitudinal directions of the inner lining of the steel ring (1).
4. The repair and reinforcement structure according to claim 1, characterized in that, The rigid epoxy resin filler layer (3) is injected under pressure through the pre-embedded grouting hole (6) to form a continuous and sealed bonding interface.
5. The repair and reinforcement structure according to claim 1, characterized in that, The surface of the steel ring liner (1) is coated with an anti-corrosion coating and a fire-resistant coating in sequence.
6. The repair and reinforcement structure according to claim 1, characterized in that, It also includes a hydraulic positioning fixture for adjusting the position of the steel ring liner (1), the fixture being detachably connected to the steel ring liner (1).
7. The repair and reinforcement structure according to claim 1, characterized in that, The pretreatment of the damaged segment (2) includes: repairing the cracks by graded grouting; welding steel mesh to the damaged area and filling it with resin; elastically filling the segment joints and reserving grouting channels.
8. The repair and reinforcement structure according to claim 1, characterized in that, The inner lining of the steel ring (1) has a tenon and mortise interlocking structure at the joint edge of each arc-shaped steel plate. An elastic sealing gasket is laid between the tenon and mortise joint surfaces of adjacent steel plates and is laterally locked by the rear expansion bolt (4).