Panel inward-winding lining method using flame-retardant press-molded resin concrete panel

Abstract

To provide a panel inward-winding lining method using flame-retardant press-molded resin concrete panels that, in addition to flame retardancy (self-extinguishing properties), also provides safety for humans from generated gases.SOLUTION: A panel inward-winding lining method using flame-retardant resin concrete panels uses a flame-retardant press-molded resin concrete panel as resin concrete panels, and comprises: a steel support assembling step of installing a steel support along an existing tunnel lining surface; a panel fixing steel material installation step of installing a panel fixing steel material to the steel support; a panel installation step of installing a resin concrete panel to the panel fixing steel material; and a grout material injection step of injecting a filling grout material into a void between a back surface (an existing tunnel side) of the resin concrete panel and the existing tunnel lining surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This invention relates to a panel inner lining method using flame-retardant resin concrete panels that are used as residual formwork (thin concrete formwork that does not need to be removed after concrete is poured) when repairing or reinforcing existing lining concrete without demolishing it, primarily when repairing road or railway tunnels.These panels are not only flame-retardant (self-extinguishing), but also safe for humans from the gases generated during combustion. [Background technology]

[0002] In road tunnels, among other civil engineering structures, fires resulting in fatalities and injuries due to vehicle accidents have occurred all over the world, and the resulting social losses cannot be ignored. (In light of this situation) Resin concrete panels used in repairing roads and railway tunnels are required to be flame-retardant (self-extinguishing), as well as not emit toxic smoke or gases when ignited and burned.

[0003] On the other hand, cracks that appear in road tunnel walls (caused by deterioration of the concrete lining over time) and the discharge of spring water from construction joints are unavoidable. In cold weather, if cracks that appear in road tunnel walls or spring water that discharges from construction joints drips onto the road surface, it can freeze and cause slip accidents, and appear as "icicles." Frozen roads and "icicles" usually form overnight, not only impeding traffic but also making it difficult for workers patrolling for safety inspections, etc. In this way, repairing road tunnel concrete lining walls also serves as a measure to prevent road surface freezing and "icicles" that occur when spring water freezes in cold regions during the winter.

[0004] Patent Document 1 addresses the issue of "providing a method for reconstructing a tunnel lining that is capable of constructing a new, highly durable inner wall surface while offering the advantages of low construction costs, a short construction period, no reduction in the tunnel cross-section after repairs, and ensuring vehicle passage through the tunnel even during repairs (Patent Document 1: Abstract)," and discloses a method for reconstructing the lining of an existing two-lane road tunnel (Patent Document 1: Title of the invention), in which "the cutting work comprises a cutting process using a cutting machine equipped with a drum cutter with a number of bits on its circumferential surface, and the inner wall surface construction work comprises a lining concrete pouring process using a lining formwork arranged so as to be movable relative to the protector within a work space formed between the inner wall surface of the tunnel and the outer wall surface of the protector (Patent Document 1: Abstract)." [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2020-139401 Summary of the Invention [Problem to be solved by the invention]

[0006] The method for reconstructing the lining of an existing two-lane road tunnel according to Patent Document 1 (Patent Document 1: Title of the Invention) allows for low construction costs, a short construction period, no reduction in the cross section of the tunnel after repair, and the construction of a new, highly durable inner wall surface made of poured lining concrete and precast concrete panels constructed using lining formwork, while preventing new defects such as cracks from occurring in the remaining part of the inner wall of the existing tunnel. However, when repairing road tunnels, the construction method using poured lining concrete and precast concrete panels constructed using lining formwork is undesirable because, because cement concrete is the base material, the width of the inwardly lining body becomes thick, violating the building gauge, and therefore requires the cutting of the existing lining concrete wall surface.

[0007] The object of the present invention is to provide a tunnel lining method (panel lining method) using a remaining formwork made of fire-retardant press-molded resin concrete panels, which can be manufactured with a curvature according to the planned cross section without having to cut or demolish the existing lining concrete, mainly when repairing roads or railway tunnels, and which is self-extinguishing in the event of a fire caused by a vehicle accident and is safe for humans from the gases generated during combustion. [Means for solving the problem]

[0008] In order to solve the above problems, the invention described in claim 1 is a tunnel lining construction method (panel lining construction method) using fire-retardant press-molded resin concrete panels that can be manufactured with a curvature according to the planned cross section when carrying out tunnel lining repair work, and that are fire-retardant (self-extinguishing) even in the event of a fire caused by a vehicle accident, and that are also safe for humans from the gases generated during combustion, The fire-retardant press-molded resin concrete panels used in tunnel lining construction (panel lining construction method) are This method is characterized by being a panel inner lining construction method using a flame-retardant press-molded resin concrete panel that is a mixture of 10wt% to 15wt% unsaturated polyester resin as a binder, 40wt% to 50wt% sand as fine aggregate, and 20wt% to 40wt% environmentally friendly hydrated metal compounds such as aluminum hydroxide or magnesium hydroxide as a flame retardant.

[0009] The invention described in claim 2 comprises a steel support assembly process for installing a steel support along the surface of an existing tunnel lining; a panel fixing steel material installation process for installing a panel fixing steel material on the steel support; a panel installation process in which a resin concrete panel is installed on the panel fixing steel material; The method includes a grout injection process for injecting a filler grout material into the gap between the back surface of the resin concrete panel (the existing tunnel side) and the surface of the existing tunnel lining, This is characterized by a panel inner lining construction method using a flame-retardant resin concrete panel, in which the flame-retardant press-molded resin concrete panel described in claim 1 is used as the remaining formwork.

[0010] The invention described in claim 3 includes an anchor installation step of installing a concrete anchor for fixing a panel along the surface of an existing tunnel lining; a panel installation process in which a resin concrete panel is installed on the panel fixing concrete anchor; The method includes a grout injection process for injecting a filler grout material into the gap between the back surface of the resin concrete panel (the existing tunnel side) and the surface of the existing tunnel lining, This is characterized by a panel inner lining method using a fire-retardant resin concrete panel, in which the fire-retardant press-molded resin concrete panel described in claim 1 is used as a surface covering material. [Effects of the Invention]

[0011] This invention is a panel inner lining construction method using flame-retardant press-molded resin concrete panels that are used as residual formwork for pouring inner reinforcement materials in order to repair and reinforce existing lining concrete walls without demolishing them when repairing roads or railway tunnels.These panels are not only flame-retardant (self-extinguishing), but also safe for humans from the gases that are generated in the event of a vehicle fire.

[0012] It includes the steps of installing steel supports along the surface of the existing tunnel lining, installing panel fixing steel materials on the steel supports, installing resin concrete panels on the panel fixing steel materials, and injecting filler grout material into the gap between the back surface of the resin concrete panel (the existing tunnel side) and the existing tunnel lining surface. Alternatively, it includes the steps of installing panel fixing concrete anchors along the surface of the existing tunnel lining, installing resin concrete panels on the panel fixing concrete anchors, and injecting filler grout material (mortar) into the gap between the back surface of the resin concrete panel (the existing tunnel side) and the existing tunnel lining surface.

[0013] The flame-retardant press-molded resin concrete panel is characterized by a blend of 10 wt% to 15 wt% unsaturated polyester resin as a binder, 40 wt% to 50 wt% sand as a fine aggregate, and 20 wt% to 40 wt% environmentally friendly hydrated metal compounds such as aluminum hydroxide or magnesium hydroxide as a flame retardant. The flame-retardant press-molded resin concrete panel of the present invention has a flame-extinguishing time (time from ignition to extinguishing) of 30 seconds or less, the tip of the fire caused by combustion does not reach a position 600 mm from the ignition point (self-extinguishing), and in a gas toxicity test, eight mice did not cease movement even after 15 minutes or more (human safety). Therefore, a panel lining construction method using a flame-retardant press-molded resin concrete panel that not only has flame retardancy (self-extinguishing) but also has human safety from the gases generated has been realized. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is an overall view of a fire-retardant press-molded resin concrete panel according to the present invention. [Figure 2] FIG. 1 is a diagram for explaining a panel lining method using a fire-retardant press-molded resin concrete panel. DETAILED DESCRIPTION OF THE INVENTION

[0015] An embodiment of a panel lining method using a fire-retardant press-molded resin concrete panel according to the present invention will be described in detail below with reference to Figures 1 and 2. Figure 1 is an overall view of a fire-retardant press-molded resin concrete panel 10 according to the present invention.

[0016] The fire-retardant press-molded resin concrete panel 10 of the present invention is a fire-retardant resin concrete panel that is not only fire-retardant (self-extinguishing) and suitable for use in repairing the inner walls of road tunnels, but is also fire-retardant and safe for humans from the gases it generates.The fire-retardant press-molded resin concrete panel 10 is a fire-retardant press-molded resin concrete panel characterized by a blend of 10 wt% to 15 wt% unsaturated polyester resin as a binder, 40 wt% to 50 wt% sand as a fine aggregate, and 20 wt% to 40 wt% environmentally friendly hydrated metal compounds such as aluminum hydroxide or magnesium hydroxide as a fire-retardant agent.

[0017] The manufacturing process for the flame-retardant press-molded resin concrete panel 10 involves measuring out the above-mentioned binder, fine aggregate, and flame-retardant additive in a predetermined ratio, mixing them so that each material is evenly dispersed, and then putting them into a mold, pressing them (including demolding), and curing them to produce the finished product (approximately 10 mm thick, approximately 1000 mm wide, and approximately 2000 mm long; the dimensions can be adjusted depending on the mold dimensions).

[0018] The fire-retardant press-molded resin concrete panel 10 is highly workable, allowing it to be easily cut to the required dimensions for the finished product, and it can also be easily drilled and curved, as shown in Figure 1. In other words, it can be curved to match the curved shape (curvature) of roads and railway tunnels (see Figure 1).

[0019] <Panel lining method using fire-retardant press-molded resin concrete panels> Figure 2 is a diagram illustrating a panel lining method using a fire-retardant press-molded resin concrete panel 10. Figure 2(a) is a diagram illustrating the panel lining method (inner reinforcement type), and Figure 2(b) is a diagram illustrating the panel lining method (surface coating type).

[0020] The panel lining method using the fire-retardant press-molded resin concrete panel 10 includes the steps of installing steel supports 20 along the surface of the existing tunnel lining, installing panel fixing steel 30 on the steel supports 20, installing the resin concrete panel 10 on the panel fixing steel 30, and injecting grout material into the gap between the back of the resin concrete panel 10 (the side of the existing tunnel) and the surface of the existing tunnel lining (inner-lining reinforcement type: see Figure 2(a)).

[0021] Alternatively, it includes the steps of installing a concrete anchor 40 for fixing a panel along the surface of the existing tunnel lining, installing a resin concrete panel 10 on the concrete anchor 40 for fixing a panel, and injecting a filler grout material into the gap between the back surface (existing tunnel side) of the resin concrete panel 10 and the surface of the existing tunnel lining (surface coating type: see Figure 2(b)).

[0022] <Effects of panel lining construction method using fire-retardant press-molded resin concrete panels> In accordance with NEXCO Test Method 738-2011 "Test method for fire spread of tunnel repair materials," a fire spread test was conducted on the fire-retardant press-molded resin concrete panel 10 used in the panel lining method using the fire-retardant press-molded resin concrete panel 10 of the present invention.

[0023] A fire-retardant press-molded resin concrete panel 10 was used as a test specimen (mounted at a 45° angle using a fixture), and the flame from the burner was aimed at the center of the panel (the ignition point) to allow the fire-retardant press-molded resin concrete panel 10 (the test specimen) to burn. The burner flame temperature reached 1200°C or higher within 30 seconds of the start of the test, and the test time was 10 minutes. The time from the removal of the flame from the burner until the combustion of the fire-retardant press-molded resin concrete panel 10 was measured. As a result, the flame extinguishing time (the time from ignition to extinguishing) of the fire-retardant press-molded resin concrete panel 10 was within 30 seconds, and the tip of the fire caused by the combustion of the fire-retardant press-molded resin concrete panel 10 did not reach a position 600 mm from the ignition point.

[0024] Furthermore, a gas toxicity test (animal experiment using mice) was conducted on the flame-retardant press-molded resin concrete panel 10. The gas toxicity test equipment consisted of a heating furnace, a stirring box, and a test box. Test specimens cut from the flame-retardant press-molded resin concrete panel 10 were heated in a heating furnace (using a propane gas burner and an electric heater) and burned. (The combustion gas generated during this process was sent from the heating furnace to a stirrer and mixed to a uniform concentration in the stirring box.) The combustion gas was cooled during mixing and then sent to a test box containing a rotating cage containing eight mice. The time until the mice in the test box ceased behavior was measured. As a result, all eight mice did not cease behavior even after more than 15 minutes had passed. Therefore, it can be said that the flame-retardant press-molded resin concrete panel 10 does not generate gas smoke or gases that are toxic to humans during evacuation.

[0025] As a result of the above, it has become possible to provide a panel inner lining construction method using a flame-retardant press-molded resin concrete panel 10 that is not only flame-retardant (self-extinguishing) and is mainly used when repairing roads and railway tunnels, but also has the safety of the gases generated to humans.

[0026] The panel lining method (inner reinforcement type), which allows for repair and reinforcement without demolishing the existing lining concrete, requires minimizing the loss of the internal cross section to meet the building limits. The fire-retardant press-molded resin concrete panel 10 is guaranteed to have a high density (due to being manufactured by press molding), and is more resistant to material permeation than general concrete materials, including water impermeability and impermeability to gases such as carbon dioxide and sulfur dioxide. The micro-particle grout mortar used as a filler is also not susceptible to carbonation. The method also includes a process for injecting a filler grout material (micro-particle grout material) into the gaps between the back side of the fire-retardant press-molded resin concrete panel 10 (the existing tunnel side) and the surface of the existing tunnel lining. In this process, fine particle grout material (fine aggregate with a particle size of 1 mm or less) is filled in, so there is no need to consider mortar cover (the distance from the surface to the framework of concrete and rebars solidified with mortar to protect the framework) or rebar gap dimensions (the minimum distance between rebars when embedding them in concrete).

[0027] Furthermore, while long-term durability is required for structural components that require strength, the high density of the fire-retardant press-molded resin concrete panel 10 (manufactured by press molding) prevents the penetration of atmospheric carbon dioxide, which promotes the neutralization of concrete components, and sulfur dioxide gases from exhaust gases. Therefore, there is no need to set a margin for the neutralization zone. For these reasons, the panel lining method (inner reinforcement type) using the fire-retardant press-molded resin concrete panel 10 can create a structure that can achieve the required allowable stress even with a very small width of the inner reinforcement cross section, making it possible to repair and reinforce the existing lining concrete without demolishing it.

[0028] <Example of modified panel lining construction method using fire-retardant press-molded resin concrete panels> The panel lining method using the flame-retardant resin concrete panel of the present invention is not limited to the aspects of the above-mentioned embodiments, and each process, such as the steel support assembly process, panel fixing steel installation process, panel installation process, and grout material injection process, can be appropriately modified as necessary within the scope of the intent of the present invention. [Industrial Applicability]

[0029] The panel inner lining method using the flame-retardant press-molded resin concrete panel of the present invention has the excellent effects as described above, and can therefore be suitably used as a panel inner lining method for remaining formwork materials using flame-retardant press-molded resin concrete panels or surface covering materials when inner-lining reinforcement repairs are carried out on roads and railway tunnels. [Explanation of symbols]

[0030] 10. Fire-retardant press-molded resin concrete panels 20...Steel shoring 30 Panel fixing steel 40··Concrete anchor for panel fixing

Claims

1. This is a tunnel lining construction method (panel lining construction method) using fire-retardant press-molded resin concrete panels that can be manufactured with a curvature according to the planned cross section used when carrying out tunnel lining repair work, and that are fire-retardant (self-extinguishing) even in the event of a fire caused by a vehicle accident, and are also safe for humans from the gases generated during combustion. The fire-retardant press-molded resin concrete panels used in tunnel lining construction (panel lining construction method) are A panel inner lining construction method using a flame-retardant press-molded resin concrete panel characterized by a blend of 10 wt% to 15 wt% of unsaturated polyester resin as a binder, 40 wt% to 50 wt% of sand as fine aggregate, and 20 wt% to 40 wt% of an environmentally friendly hydrated metal compound, such as aluminum hydroxide or magnesium hydroxide, as a flame-retardant agent.

2. A steel support assembly process in which steel supports are installed along the surface of the existing tunnel lining; a panel fixing steel material installation process for installing a panel fixing steel material on the steel support; a panel installation process in which a resin concrete panel is installed on the panel fixing steel material; A grout injection process is provided in which a filler grout material is injected into the gap between the back surface of the resin concrete panel (the existing tunnel side) and the existing tunnel lining surface, 2. A panel inner lining construction method using a fire-retardant press-molded resin concrete panel, characterized in that the fire-retardant press-molded resin concrete panel according to claim 1 is used as a remaining formwork.

3. an anchor installation process in which concrete anchors for fixing panels are installed along the surface of the existing tunnel lining; a panel installation process in which a resin concrete panel is installed on the panel fixing concrete anchor; A grout injection process is provided in which a filler grout material is injected into the gap between the back surface of the resin concrete panel (the existing tunnel side) and the existing tunnel lining surface, 2. A panel inner lining construction method using a fire-retardant press-molded resin concrete panel, characterized in that the fire-retardant press-molded resin concrete panel according to claim 1 is used as a surface covering material for the resin concrete panel.

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