DEVICE FOR TAKING ROCK DEFORMATIONS IN UNDERGROUND ENGINEERING, METHOD FOR PRODUCEING A REINFORCING LAYER SUITABLE FOR TAKING ROCK DEFORMATIONS IN UNDERGROUND ENGINEERING AND USE OF A POLYSTYRENE CHUNKING ELEMENT AND METHOD FOR PRODUCEING SUCH A DEVICE

Description

[0001] The present invention relates to a device for absorbing rock deformations in underground mining, a method for producing a bonding layer suitable for absorbing rock deformations in underground mining, the use of a polystyrene compression element and a method for producing such a device.

[0002] In underground mining, the rock mass in which the excavation takes place typically continues to deform for a certain period of time after the excavation is complete. Therefore, excavated cavities or tunnels are regularly secured against deformation and / or at least partial collapse with a shotcrete lining or tunnel segments. The shotcrete lining or the tunnel segments generally do not deform as easily as the surrounding rock mass they support. This can lead to stresses and deformations within the shotcrete lining or the tunnel segments, which can cause damage. To prevent damage such as cracks, o.ä.To avoid problems in the shotcrete shell, it is common practice to equip the shotcrete shell with compression elements, which, in combination with the shotcrete, ensure a planned, controlled flexibility and deformability of the tunnel lining.

[0003] Compression elements made of various materials are known from the prior art. Compression elements comprising concrete, plastic, or steel and containing reinforcing elements are known, as for example from EP 1564369 B1. Compression elements with pipes arranged with their longitudinal axis either radially or tangentially to the shotcrete shell are also known, as for example from EP 2918772 A2.

[0004] Document US 4,483,642 A reveals a barrier device for a tunnel.

[0005] The known compression elements, based on the state of the art, have the disadvantage of being heavy and unwieldy. Installation generally requires at least two people, making it complex and expensive. Furthermore, these known compression elements are composed of various shapes and materials. The load transfer between the surfaces of the compression elements resting on the shotcrete shell is not optimal with the existing elements. Due to their composition from different materials and shapes (pipe, cuboid, etc.), it is also difficult for users on the construction site to individually adapt their geometric form to the specific installation conditions. Finally, the composition of existing compression elements from different materials and shapes makes them complex to manufacture and therefore expensive.

[0006] The object of the invention is therefore to overcome the disadvantages of the prior art and in particular to provide a device for absorbing rock deformations in underground construction, a method for producing a reinforcement layer suitable for absorbing rock deformations in underground construction, a method for producing such a device, and a use of a polystyrene compression element for absorbing rock deformations in tunnel construction, which is easy to install and flexibly adaptable to the required dimensions and forces.

[0007] The problem is solved by a device, a manufacturing process for a fastening layer, a method for manufacturing a device and the use of a polystyrene compression element according to the independent claims.

[0008] In particular, the problem is solved by a device for absorbing rock deformations in underground mining, especially a compression element, wherein the device has a base, a height, and a depth and comprises polystyrene. The device preferably comprises expanded polystyrene, and in particular, preferably high-strength expanded polystyrene.

[0009] Polystyrene exhibits non-linear, hyper-elasto-plastic deformation behavior. Such a device enables optimal compression behavior and results in a permanent bond between the rock and the shotcrete lining. Further advantageous properties of polystyrene include its robustness against environmental influences and its exceptional durability. Polystyrene is essentially rot-proof and insensitive to moisture. Furthermore, polystyrene exhibits high resistance to chemical influences and high corrosion resistance. This allows the devices to be used even under harsh conditions in underground mining. (e.g. Polystyrene can be used in various environments, including areas with high humidity (moisture) and generally on construction sites. Due to its chemical and corrosion resistance, polystyrene can also be used in groundwater.

[0010] Due to the advantageous deformation properties of polystyrene, tangential forces can be transferred across the entire surface of the shotcrete shell. This uniform force distribution prevents areas with particularly high and areas with particularly low force transmission. Thus, the force is introduced into the shotcrete in a largely uniform and therefore gentle manner, avoiding areas of excessive stress. This reduces damage and spalling of the shotcrete shell and allows for optimal dimensioning of the shotcrete shell.

[0011] The polystyrene may contain a polymeric flame retardant. This makes the polystyrene difficult to ignite and thus gives it favorable fire behavior. As a result, virtually no smoke is produced.

[0012] Polystyrene can exhibit self-extinguishing behavior.

[0013] This means that the compression elements can also be used underground, and essentially no additional fire protection equipment is required when using polystyrene.

[0014] The devices preferably contain essentially no reinforcing elements such as pipes or rods. This allows for simple and therefore cost-effective manufacturing.

[0015] The device can be made of polystyrene.

[0016] Due to the simple construction of the devices, which are essentially made from a single material, the devices are particularly inexpensive to manufacture, easy to process and easy to use.

[0017] The devices can essentially be cuboid in shape.

[0018] The cuboid shape makes the devices stackable and easy to produce and install.

[0019] The length of the device can be greater than its height and / or depth.

[0020] This design allows the devices to be manufactured, stacked, transported, and installed easily and without complications. For example, the device can have a length of 80 cm, a height of 30 cm, and a depth of 25 cm. Other dimensions are, of course, also possible.

[0021] The device can be composed of several element layers, with the element layers arranged on top of each other along the height extent.

[0022] This advantageous design of the device makes it possible to produce the device in different heights or to quickly and easily adapt its height to the prevailing conditions on site. It is possible to separate the layers of a compression element using tools commonly available on construction sites (e.g., a saw) or to add further layers to a compression element. The added layers can be fixed, for example, with adhesive or mechanical fasteners such as wires, screws, or clamps. Adhesive allows for particularly easy joining of the elements.

[0023] Furthermore, it is possible to individually modify the shape of the individual element layers or the compression element as a whole. This can also be done using tools that are generally available on a construction site, such as saws or knives. This allows the compression element to be adapted to the specific installation conditions on the site. As a result, in practice, the compression element can be easily adapted to different conditions by a single user. Naturally, the devices can contain other materials in small quantities, such as adhesives or fasteners. These additional materials do not substantially alter the deformation properties of the device.Additional materials are added to the device essentially to optimize the manufacturing and / or installation of the device, and not to influence the deformation behavior of the device.

[0024] The device can comprise at least two different densities, in particular at least two, preferably three, element layers of different densities.

[0025] The devices can therefore contain polystyrene of varying densities. By using different densities, the deformation behavior can be individually tailored to the expected rock deformation. The polystyrene can exhibit deformation behavior comprising a linear-elastic zone, a flow zone, and a compression zone. In the linear-elastic zone, the stress increases essentially directly proportionally with the compression. The linear-elastic zone lies essentially between 2 percent and 5 percent of the polystyrene's compression. In the flow zone, the polystyrene's compression increases, while the stress increases only moderately. The flow zone lies essentially between 5 percent and 60 percent of the polystyrene's compression. In the compression zone, the stress increases, while the compression increases only slightly.The compaction essentially takes place when the polystyrene is compressed by 60 percent.

[0026] By designing the device with element layers of varying densities, it is possible to produce a device with specific deformation properties. This allows for the manufacture of compression elements that are specifically adapted to the local geological conditions. Furthermore, the standardized structure of the device, consisting of element layers, makes it possible to produce a wide variety of devices with different deformation properties using a range of essentially cuboid element layers with only a few different densities.

[0027] A symmetrical arrangement of layers of different densities can be formed, such that two layers of the same density are present in each device. A single middle layer can also be included.

[0028] By providing element layers in three different densities, a large number of devices with different deformation properties can be produced particularly advantageously by constructing the device from several element layers.

[0029] Thus, a wide variety of compression elements can be easily and simply manufactured using standardized element layers with varying densities, adapted to the specific geological conditions at the construction site. Manufacturing facilities only need to be designed for producing element layers with a few different densities, while the final products (compression elements), which comprise element layers of varying densities, can be manufactured with a wide range of deformation properties.

[0030] It is possible for the compression elements ordered for the construction site to be manufactured in a factory with the desired properties. It is also conceivable that the element layers, in several densities, are manufactured in a factory and delivered to the construction site as individual layers. On site, several layers of elements with the same or different densities can then be assembled. Thus, both the manufacturing of the compression elements in a factory and the manufacturing of element layers in a factory, followed by delivery of these layers as semi-finished products to the construction site and subsequent assembly of the semi-finished products into a finished product (compression element) that can then be installed, are conceivable.

[0031] In another embodiment of the invention, the device can have a lower density along its outer height than in the middle region.

[0032] This advantageous design of the invention allows the device to conform to the shotcrete along its outer vertical dimension, where the force is applied. This compensates for irregularities that regularly occur in shotcrete. As a result, a favorable force transmission to the shotcrete is possible across essentially the entire contact surface between the compression element and the shotcrete. Thus, the force from the compression element can be transferred into the shotcrete across the entire contact area. This ensures a large-area and gentle force transmission, minimizing the risk of damage to the shotcrete.

[0033] In a further advantageous embodiment of the invention, the device has a density in the range of 100 kg / m³ to 500 kg / m³. In particular, the element layers essentially each have a density between 230 kg / m³ and 410 kg / m³.

[0034] At the specified density, the device compresses before the shotcrete is significantly damaged. Simultaneously, the device is sufficiently rigid to withstand the pressure of the surrounding rock mass in conjunction with the shotcrete. Therefore, at the specified densities, the device exhibits the deformation properties necessary to function effectively in conjunction with the shotcrete shell.

[0035] In a further advantageous embodiment of the invention, the device has a weight of less than 40 kg.

[0036] Due to the device's weight of less than 40 kg, it can be installed by a single user. This makes installation of the device inexpensive.

[0037] The object of the invention is further achieved by a method for producing a stabilizing layer suitable for absorbing rock deformations in underground mining, wherein the stabilizing layer comprises an inner layer, in particular a shotcrete layer or a layer of tunnel segments, and a device as described above is arranged in the inner layer.

[0038] By integrating the device into the inner layer, it can be easily installed from the inside by a user. Furthermore, the correct installation and compression of the devices can always be visually inspected.

[0039] The device can first be placed on a radially arranged surface in the area of ​​the future shotcrete shell and then fixed in place. Alternatively, the device can first be suspended from a horizontal mounting element or placed on a horizontal mounting element and then secured using fasteners. The horizontal mounting element can be made of steel, plastic, a composite material, or another suitable material. The installation method is therefore extremely simple and flexible.

[0040] The reinforcement layer can include a reinforcement grid on the mountain side, which is arranged between the inner layer and the mountain.

[0041] The mounting grid can advantageously absorb the tensile forces in the shotcrete and facilitate the installation of the device. The mounting grid can be made of steel or plastic, for example. It can also be made of a composite material. The device can be advantageously attached to the mounting grid. This can be done, for example, by tying straps, ropes, or other fasteners around the device and looping them around one or more elongated horizontal or vertical grid elements. Alternatively, the device can be attached to a substantially cylindrical mounting element using hooks. The hooks can be made of steel.The hooks can be recessed into the device at one end and have a substantially hook-shaped form at the other, allowing the device to be attached to the mounting element by means of the substantially hook-shaped ends of the hooks. It is conceivable that the second end of the hooks could be shaped like a circular segment. Other hook shapes, for example, with one or more angles and / or bends, are also possible. The advantageous arrangement of the mounting element allows the device to be transported very conveniently by a user. Furthermore, the mounting element can be used for installation by either hooking the device onto the mounting grid with the mounting element or by placing the device onto a mounting element suspended in the mounting grid.The device can then be attached to the mounting grid using additional fasteners, such as wires, straps, or cable ties. This type of installation is very simple and straightforward. As a result, the device can be installed on construction sites using equipment commonly found there.

[0042] The device's height can be tangential to the cavity. The device's base can be radial to the cavity.

[0043] This arrangement of the device makes bending, tilting, or lateral-torsional buckling extremely unlikely, and the device is highly likely to be compressed as intended. This ensures a high level of reliability for the device.

[0044] The fastening layer can comprise at least two fastening arches, with the device positioned between the two fastening arches. The device can rest on a fastening element or be suspended from a fastening element that connects the fastening arches. In this arrangement, the fastening element is positioned along the longitudinal axis of the cavity created in the underground construction.

[0045] By incorporating mounting brackets into the invention, the device can be installed particularly advantageously by inserting a fastening element between the mounting brackets in a substantially horizontal direction. The fastening element can be a rod, for example, made of steel or plastic. The device can be placed on the fastening element or suspended from it. The device can be installed particularly advantageously by hooking the fastening element onto the two hooks located on the device and then, with the attached device, first hooking it into a first mounting bracket and then into a second mounting bracket.The device can also be installed by first hooking the mounting element into the first mounting bracket and then into the second, and then attaching the device to the mounting element using the hooks or placing it on top of the mounting element. The device can then be secured to the mounting grid with wires, straps, cable ties, or other fasteners. This installation method is simple, straightforward, and less prone to errors.

[0046] The object of the invention is further solved by the use of a polystyrene compression element to absorb rock deformations in tunnel construction, in particular a polystyrene compression element with layers of different density.

[0047] The use of a polystyrene compression element to absorb rock deformations in tunnel construction is a simple, cost-effective and uncomplicated method to absorb the deformations that occur in tunnel construction, for example in a shotcrete lining or in tunnel segments.

[0048] The object of the invention is further achieved by a method for manufacturing a device as described above, wherein the device is assembled from several polystyrene bodies. The polystyrene bodies can be cuboid in shape. Furthermore, the polystyrene bodies can be joined together by gluing.

[0049] A method for manufacturing a device from multiple polystyrene bodies is extremely straightforward and flexible. The device can be composed of two or more polystyrene bodies. Each polystyrene body then corresponds to one layer of a device for absorbing rock deformations. It is conceivable to join polystyrene bodies of different densities. The polystyrene bodies can be joined by gluing. Fastening the polystyrene bodies to each other with other fasteners, such as screws, nails, pins, cable ties, straps, or chains, is also possible.

[0050] The invention is explained in more detail in the following figures.

[0051] This shows: Fig. 1: A device for absorbing rock deformations in underground mining, in particular a compression element; Fig. 2: A device for absorbing rock deformations in underground mining, in particular a compression element, installed in a shotcrete shell; Fig. 3: An exemplary stress-strain diagram of polystyrene with a linear-elastic zone, a flow zone, and a compaction zone; Fig. 4: A schematic representation of different exemplary arrangements of several element layers of a device for absorbing rock deformations with the same or different densities; Fig. 5: A schematic cross-section of a tunnel with four exemplary arrangements of devices for absorbing rock deformations; Fig. 6: A device for absorbing rock deformations in underground mining, in particular a compression element, with a retaining grid, two hooks, a horizontal fastening element, and two fastening arches.Fig. 7: A view of a variety of devices for absorbing rock deformations in underground mining, installed in the shotcrete lining of a tunnel, Fig. 8: A cross-section of a segment of a shotcrete tunnel lining with a built-in device for absorbing rock deformations in underground mining, Fig. . 9: A view of a segment of a tunnel lining in the construction state with a built-in device for absorbing rock deformations in underground construction, a horizontal fastening element, two fastening arches and a retaining grid.

[0052] Figure 1Figure 1 shows a device for absorbing rock deformations in underground mining, in particular a compression element 1, with an exemplary arrangement of several element layers 2, wherein the compression element 1 in this example is cuboid and its longitudinal extent is greater than its vertical extent and / or its depth extent. The compression element 1 is composed of six element layers 2. Furthermore, the compression element 1 in this example has a longitudinal extent of 80 cm, a vertical extent of 30 cm, and a depth extent of 25 cm.

[0053] Figure 2Figure 1 shows a device for absorbing rock deformation in underground mining, in particular a compression element 1 installed in a shotcrete shell 3. The compression element 1 is essentially cuboid in shape, with its height oriented tangentially to the cavity and its base radially oriented to the cavity. The base of the compression element 1 fits snugly against the shotcrete shell 3, ensuring advantageous force transmission between the compression element 1 and the shotcrete shell 3. The dimensions of the compression element 1 and its arrangement within the recess of the shotcrete shell 3 ensure that, when force is applied by the shotcrete shell 3, the compression element 1 is unlikely to tip and highly likely to compress, thus absorbing forces from the shotcrete shell 3 and any deformation of the shell.

[0054] Figure 3 Figure 1 shows an exemplary stress-strain diagram of polystyrene with a substantially linear-elastic zone 4, a flow zone 5, and a compression zone 6. The stress-strain diagram of the respective compression element (not shown) can be advantageously adapted by varying the density of the element layers 2, so that the properties of the compression element (not shown) can be advantageously adapted to the given conditions and technical requirements in the specific application.

[0055] Figure 4Figure 1 shows a schematic representation of different exemplary arrangements of several element layers 2 of a device for absorbing rock deformations with the same or different densities. The element layers 2 of a compression element 1, if they have different densities, can be arranged such that the element layers 2 with the higher density are located on the outside in the vertical extent. The element layers 2 can also be arranged such that the element layers 2 with the lower density are located on the outside in the vertical extent. An asymmetrical arrangement of the element layers 2 with respect to density along the vertical extent of the compression element 1 is also conceivable.It is possible that the two outer element layers 2 with respect to height expansion have the highest and lowest densities of the element layers 2 of the compression element 1, while the element layers 2 enclosed by the outer element layers 2 have a density that lies between the highest and lowest densities of the element layers 2 of the compression element 1.

[0056] Figure 5 Figure 1 shows a schematic cross-section of a tunnel with four exemplary devices for absorbing rock deformations (compression elements), wherein the heights of the compression elements 1 are arranged tangentially to the cavity and the bases of the compression elements 1 are arranged radially to the cavity. In the Figure 5The compression elements 1 are arranged by way of example in the crown and in the nave of the tunnel cross-section. It is possible for the compression elements 1 to be arranged in any area of ​​the shotcrete lining 3. It is also possible for several compression elements 1 to be arranged in direct contact such that their base surfaces touch. A single compression element 1 or a multitude of compression elements 1 can be installed in the cross-section. The compression elements 1 can be arranged axially symmetrically or point-symmetrically. An asymmetric arrangement of the compression elements 1 is also possible.

[0057] Figure 6Figure 1 shows a device for absorbing rock deformations in underground mining, in particular a compression element 1 with a retaining grid 7, two hooks 8, a horizontal fastening element 9, two fastening brackets 10, and a wire 11. The advantageous attachment of the hooks 8 to the compression element 1 allows for advantageous processing and installation of the compression element 1. The hooks 8 can be made of steel, plastic, a composite material, or another suitable material. In this example, the hooks 8 are made of steel. At a first end, the hooks 8 are connected to the compression element 1 by being embedded in the compression element 1 at their first end. At a second end, the hooks 8 are hook-shaped. The hook-shaped second end of the hooks 8 is attached to a substantially horizontal fastening element 9.The second end of the hooks 8 is semicircular in this example. The compression element 1 is attached to a horizontal fastening element 9 by means of the hooks 8. In this example, the horizontal fastening element is essentially a cylindrical steel rod. The horizontal fastening element 9 is hooked into the two fastening brackets 10. In this example, the compression element 1 is secured by a wire 11. This allows the compression element 1 to be moved into a desired position, enabling the installation of the shotcrete shell 3, and makes it extremely unlikely that the compression element 1 will shift significantly during the installation of the shotcrete shell. This ensures that the compression element 1 remains in the intended position during the subsequent construction work. It is also conceivable that the compression element 1 could be fixed to the support grid with cable ties, straps, belts, hoses, or other fasteners.

[0058] Figure 7Figure 1 shows a view of a variety of devices for absorbing rock deformation in underground mining (compression elements), installed in the shotcrete shell 3 of a tunnel lining. In this installed state, the retaining grid is covered by the shotcrete shell 3 or by the compression elements 1 and is no longer visible or only partially visible. The height of the compression elements 1 is oriented tangentially to the cavity in the shotcrete shell 3, and the base of the compression elements 1 is arranged radially to the cavity. Due to this advantageous orientation of the compression elements 1 in the shotcrete shell 3, tilting, bending, or lateral-torsional buckling of the compression elements 1 is extremely unlikely. Thus, it is very probable that the compression elements 1 will compress as intended. In conjunction with the shotcrete shell, the system's function is therefore very reliable. Furthermore, the compression elements are visible in their installed state.This allows the compression elements 1 to be advantageously checked visually by a user or by appropriate measuring equipment for their correct fit and correct function.

[0059] Figure 8 Figure 1 shows a cross-section of a segment of shotcrete tunnel lining with an integrated device for absorbing rock deformation in underground construction (compression element). Here, the compression element 1 is placed on a horizontal fastening element 9. The compression element 1 can be fixed by one or more wires 11.

[0060] This allows the compression element 1 to be moved into the desired position, enabling the installation of the shotcrete lining 3. It is extremely unlikely that the compression element 1 will shift significantly during the installation of the shotcrete lining 3. This ensures that the compression element 1 remains in its intended position during the subsequent construction work. The height of the compression elements 1 is oriented tangentially to the tunnel cavity, and the base of the compression elements 1 is arranged radially to the cavity. The height of the element layers 2 is also oriented tangentially to the tunnel cavity. The surfaces on which the individual element layers 2 rest are therefore oriented radially to the tunnel cavity.

[0061] Figure 9Figure 1 shows a view of a segment of a shotcrete tunnel lining with an integrated device for absorbing rock deformation in underground mining (compression element). A retaining grid 7 is installed on the mountain side between the compression element 1 and the rock. The compression element 1 is fixed to the retaining grid 7 by one or more wires 11. The compression element 1 also rests on a horizontal fastening element 9. The horizontal fastening element 9 is suspended in two fastening brackets 10.

Claims

1. Device for accommodating rock deformations in underground mining, in particular a yielding element (1), wherein the device has a base area, a height extension and a depth extension, characterized in that the device comprises high-strength expanded polystyrene.

2. Device according to claim 1, characterized in that the device consists of polystyrene.

3. Device according to one of the preceding claims, characterized in that the device is essentially cuboid-shaped.

4. Device according to claim 3, characterized in that the longitudinal extension is greater than the height extension and / or the depth extension.

5. Device according to one of the preceding claims, characterized in that the device is composed of a plurality of element layers (2), wherein the element layers (2) are arranged on top of one another along the height extension.

6. Device according to one of the preceding claims, characterized in that the device comprises at least two different densities, in particular at least two, preferably three, element layers (2) of different density.

7. Device according to claim 6, characterized in that the device has a lower density on the outside along the height extension than in the central region.

8. Device according to one of the preceding claims, characterized in that the device has a density in the range of 100 kg / m3 to 500 kg / m3, in particular the element layers (2) essentially each have a density between 230 kg / m3 and 410 kg / m3.

9. Device according to one of the preceding claims, characterized in that the device has a weight of less than 40 kg.

10. Method for producing a support layer suitable for accommodating rock deformations in underground mining, wherein the support layer comprises an inner layer, in particular a shotcrete layer or a layer of tubbings, characterized in that a device according to one of the preceding claims is arranged in the inner layer.

11. Method according to claim 10, characterized in that the support layer comprises, on the rock side, a support grid, which is arranged between the inner layer and the rock.

12. Method according to one of claims 10 to 11, characterized in that the height extension of the device is arranged tangentially to the cavity and preferably the base area is arranged radially to the cavity.

13. Method according to one of claims 10 to 12, characterized in that the support layer comprises at least two support arches (10) and the device is arranged between the two support arches (10) and in particular rests on a fastening element (9) which connects the support arches (10), such that the fastening element (9) is arranged along the longitudinal axis of the cavity.

14. Use of a device for accommodating rock deformations in underground mining according to one of claims 1 - 9 with element layers (2) of different density for accommodating rock deformations in tunnel construction.

15. Method for producing a device for accommodating rock deformations in underground mining according to one of claims 1 - 9, wherein the device is assembled, in particular glued, from a plurality of, in particular cuboid-shaped, polystyrene bodies.