Method and system for constructing underground structures

Abstract

Jet grouting involves injecting grout into geological materials to improve their quality. However, the use of jet grouting is limited to situations where the injection system can be positioned relatively close to the area to be improved. However, such jet grouting systems lack the precision to form complex, stable structures. The present invention makes it possible to build underground structures before excavation is performed by casting blocks in situ. Specifically, structural blocks can be formed from grouting compounds and / or cement in the shape of the tunnel to be excavated and / or around an underground asset (such as a depleted nuclear waste container).

Description

[Technical Field]

[0001] The present invention relates generally to methods and systems for constructing underground structures and finds particular, but not exclusive, utility in tunnel construction. [Background technology]

[0002] Pressure grouting and jet grouting are well-known techniques in which grout is injected into geological materials (e.g., soil, sand, and / or rock) to improve their quality, e.g., to correct defects, improve their strength, and / or reduce water flow through them. Such grouting techniques are often used around the foundations of large structures (buildings, bridges, etc.) and around underground structures, including large pipes and tunnels. Typically, in pressure grouting, grout is injected into the geological material to fill any interconnected pores and voids to stabilize it without disturbing the existing material. In contrast, jet grouting is typically achieved with a relatively high-velocity grout jet, which is used to erode the geological material in situ, mix a significant amount, and often form a unique shape (e.g., a pillar and / or platform).

[0003] However, such jet grouting systems lack the precision to form complex and stable structures. Summary of the Invention

[0004] According to a first aspect of the present invention, there is provided a method of constructing an underground structure, the method comprising the steps of excavating an underground bore through bedrock geology, lining the bore with a pipe, moving a cutting device through the pipe to a predetermined location, cutting a three dimensional volume outside the pipe using the cutting device, moving a deployment device through the pipe to a predetermined location, and deploying material in the three dimensional volume using the deployment device.

[0005] In this manner, underground structures may be constructed before excavation is performed. Specifically, structural blocks may be formed from grouting compounds and / or cement (e.g., including concrete / composite materials incorporating aggregates such as sand, gravel, crushed stone, slag, or recycled crushed concrete) in the shape of the tunnel to be dug and / or around an underground asset (e.g., a depleted nuclear waste container). That is, the building blocks may be cast in situ by forming a mold from the underlying geology.

[0006] The cutting device may include an articulating and / or flexible arm that can be manipulated through the hole in the pipe and controlled to drill a desired three-dimensional volume. The cutting device may include a cutting head on one end of the arm, which may be interchangeable with cutting heads having different roughnesses. For example, a coarse cutting head may be used to quickly form a large open space within the three-dimensional volume. A precision cutting head may be used to shape the large open space to the desired shape, i.e., to fit the desired three-dimensional volume. Cutting the outer three-dimensional volume of the pipe may include performing a coarse cut using the coarse cutting device, followed by performing a precision cut using the precision cutting device.

[0007] Cutting can include using fluids, such as water, drilling mud, and / or slurry (e.g., a mixture of water and clay), in a three-dimensional volume. For example, the pressure of the mud and / or slurry can prevent surrounding material from crumbling in the cutting volume. Furthermore, if the fluid is pumped through the volume at a sufficiently high velocity, broken rock fragments can be carried away by the fluid flow.

[0008] The method may further include moving the cutting device to a second predetermined location within the pipe, using the cutting device to cut a second three-dimensional volume outside the pipe adjacent to the first three-dimensional volume, moving the deployment device to the second predetermined location, and using the deployment device to deploy the material in the second three-dimensional volume.

[0009] Alternatively or additionally, the method may further include providing a second cutting device to the second pipe or pipes at a second predetermined location, using the second cutting device to cut a second three-dimensional volume outside the pipe adjacent to the first three-dimensional volume, moving the second deployment device (or moving the first deployment device) to the second predetermined location, and deploying material in the second three-dimensional volume using the first / second deployment devices.

[0010] In this manner, a structure can be constructed from adjacent blocks, e.g., making the structure waterproof. In some arrangements, the or each block can be surrounded by a sealant, such that adjacent blocks are joined by a gasket to prevent leakage between them. For example, a sealant can be introduced into the first and / or second three-dimensional volumes to coat the interior of the volumes before the material is deployed in the volumes.

[0011] The first and second three-dimensional volumes may be configured to interdigitate with one another, i.e., one or each of the volumes may have a recess into which the other volume is positioned to protrude, forming an interdigitated stable structure that provides sufficient stability for subsequent operation.

[0012] Optionally, the first block may be hardened / cured before cutting the second three-dimensional volume, so that material may not leak from one block into adjacent blocks or from the first block.

[0013] Subsurface may refer to any subsurface location. Surrounding geology may refer to the geological material adjacent to a given location, and may be within the bedrock geology.

[0014] The deployment may include deployment of a material. The deployment may include injection / introduction (e.g., injection / introduction of a material).

[0015] Materials may include grouts and / or repair substances such as epoxy resins, polyurethane foams, polyurethane resins, acrylic resins, cement grouts, and aqueous solutions. Treatment materials may include concrete / composite materials incorporating aggregates such as sand, gravel, crushed stone, slag, or recycled crushed concrete. Grouts may be chemical mixtures of cements, resins, or solutions.

[0016] Each block produced by the method of the present invention may be identical to every other block or may be tailored to its specific environment and / or end use. For example, grout formulations may be selected for some blocks to favor compressive strength, permeability, corrosion resistance, appearance, etc.

[0017] The or each block may be provided with structural reinforcement members, for example, by introducing rebar and / or metal coils into the volume prior to deploying the material in the volume. As an alternative or in addition to introducing structural reinforcement members into the volume, sensor devices (ground penetrating radar transceivers, connecting wires, seismic equipment, etc.) may be introduced prior to deploying the material in the volume. In particular, the structural reinforcement members and / or sensor devices may be deployed from pipes, in particular from carriages within the pipes.

[0018] Prior to cutting the three-dimensional volume, the method may further include moving the treatment equipment through the pipe to a predetermined location and deploying the treatment material into the underlying geology.

[0019] The treatment materials may include grouts and / or repair substances such as epoxy resins, polyurethane foams, polyurethane resins, acrylic resins, cement grouts, and aqueous solutions. The treatment materials may include concrete / composite materials incorporating aggregates such as sand, gravel, crushed stone, slag, or recycled crushed concrete. The grout may be a chemical mixture of cement, resin, or solution.

[0020] Treating can include stabilizing the bedrock geology. In this way, if the material outside the region is relatively weak, porous, unstable, or waterlogged, the material can be stabilized. Equipment can be installed down the bore to stabilize the bedrock geology outside the pipe.

[0021] Stabilization can be achieved using ground freezing techniques, for example, by pumping cooling fluid through holes in the pipe. The freezing techniques can be temporary. Permanent stabilization can be achieved, for example, by deploying chemical stabilizers using chemical delivery nozzles (e.g., in a telescoping arm). The amount and type of stabilizer used is determined by the geology being stabilized and can be controlled as needed. The stabilizer can include cement or any other suitable material, such as microcement, mineral grout (also known as colloidal silica), water-sensitive polyurethane (a fast-reacting foaming resin to combat water intrusion), fast-reacting and non-water-sensitive polyurea silicate systems (expanding foams for void filling), acrylic resins, jet grouting (i.e., building solidified ground to design features in-situ), and concrete / composite materials incorporating aggregates such as sand, gravel, crushed stone, slag, or recycled crushed concrete (often known as soil-crate (RTM)).

[0022] If further water infiltration cannot be completely prevented, the stability of the bedrock may be significantly reduced.

[0023] Drilling underground bores through bedrock geology can involve using directional boring techniques used in the mining, oil and gas, and construction industries. For example, horizontal directional drilling (HDD) is used to install pipes, etc. HDD is capable of properly drilling precise bores with diameters ranging from 100mm to 1200mm, and lengths up to 800m. Alternatively, directional drilling is used in the oil and gas industry, allowing for much longer bores to be drilled.

[0024] The method may include excavating the bedrock geology from around the three-dimensional volume once the bedrock geology has hardened into a block.

[0025] The pipe may include a liner for lining the bore. In this way, the integrity of the bore may be protected. The liner may include lining the entire bore or only a portion of the bore. The liner may have a solid wall.

[0026] The hole may comprise a single hole or multiple holes. The hole(s) may comprise any form of opening, such as a circular through-hole, a slot, etc.

[0027] Prior to cutting the three-dimensional volume, the method may further include moving a drilling device (e.g., an excavator or some other form of equipment for making holes) through the bore along a predetermined path to a predetermined location, and / or using the drilling device to make hole(s) at least partially through the pipe at the predetermined location(s). The hole(s) may be made by drilling, perforating, milling, punching, scraping, cutting, and / or any other suitable method.

[0028] In this way, a method is possible in which the material is deployed through a pipe.

[0029] The drilling equipment may include a carriage on which a drill is mounted, or some other form device for creating the hole(s). The drill / device may be retractable (e.g., telescopically, longitudinally, and / or pivotally). The device may include, for example, a milling head that indexes around, which may be configured to create a single or various shapes of openings in the pipe.

[0030] The method may further include using the equipment to create a hole at most partially through the pipe at a predetermined location.

[0031] In this way, foreign material and / or water may be prevented from entering the bore in an uncontrolled manner. Specifically, the holes may extend almost entirely through the pipe wall (e.g., extending less than 2 mm, specifically less than 1 mm from the outer surface of the pipe wall).

[0032] In alternative arrangements, the drill / device may be configured to drill holes, pipes entirely through, or even excavate into the surrounding geology, etc.

[0033] The pipe may include a hole prior to insertion into the bore.

[0034] For example, the pipe may be pre-drilled. In this way, in situations where the underlying geology is well understood, time and costs may be avoided on-site. The pre-drilled liner may include an outer sleeve that covers the perforations. In this way, outside material and / or water may be prevented from entering the bore in an uncontrolled manner. The outer sleeve may be relatively easy to push or cut, thereby allowing desired access to the outside of the pipe while preventing unexpected infiltration into the pipe.

[0035] For example, various devices may be configured to penetrate pipe walls, specifically, either small amounts of pipe wall remaining, such as after drilling, or a sleeve of pre-drilled pipe.

[0036] The pipe and / or liner may comprise a plastic material as is well understood in the art.

[0037] Various pieces of equipment (including excavators and / or deployment equipment) may penetrate the pipe in a conventional manner to perform operations at any desired location. For example, carriages may be provided on which specific equipment may be mounted and / or the carriages may form part of the equipment. A train of carriages may be provided such that different pieces of equipment may travel through the pipe as a single train to predetermined locations. For example, a single train may have a first carriage configured to determine a location along the pipe, a second carriage configured to drill a hole in the pipe, and a third carriage configured to deploy material through the hole. As can be appreciated, multiple pieces of equipment may be mounted on a single carriage, such that the above-described, similar, or different effects may be achieved with fewer (or more) carriages.

[0038] Two or more carriages and / or trains may travel within a single pipe, performing similar and / or coordinated tasks, for example, simultaneously, at different predetermined locations along the pipe, or sequentially at different times.

[0039] Similarly, multiple carriages and / or trains may coordinate together by operating either simultaneously or sequentially at different times, and may coordinate from the same pipe / bore, as well as even different / separate pipes / bores. For example, if multiple bores are being drilled and lined around a single asset, each carriage / train may pass through each bore (e.g., to simultaneously deploy material / grout), and / or two or more carriages / trains may pass through a single bore / pipe (e.g., to provide monitoring of the asset from two or more predetermined locations along a single bore / pipe).

[0040] The carriage / train may be configured to rescue a broken carriage / train, for example by supplying power to it or by attaching it to the broken one and removing it from the bore / pipe.

[0041] For the avoidance of doubt, a default location may include a single location or multiple locations.

[0042] Excavation operations may be carried out from pre-constructed tunnel entrances and / or exits, intermediate shafts, and / or from the surface.

[0043] The bores may comprise holes and / or shafts of substantially circular cross section, with lengths several orders of magnitude greater than their diameters. For example, each bore may have a diameter of 100 mm to 1200 mm. Each bore may have a length of at least 25 m, at least 50 m, at least 100 m, at least 200 m, or more.

[0044] The method may include determining the first default route (and optionally the second default route), however this is done in a conventional manner.

[0045] The bore may have a length of at least 25 m, or less than 25 m. For example, the first bore may have a length of at least 5 m, 10 m, 15 m, and / or 20 m. However, other features of the second embodiment may be common to the first embodiment.

[0046] According to a second aspect of the present invention there is provided a system for carrying out the method of constructing an underground structure according to the first aspect, the system comprising: a directional drilling rig for drilling an underground bore through bedrock geology; a pipe for lining the bore drilled by the directional drilling rig; a pipe lining device for lining the bore with the pipe; a cutting device configured to move through the pipe to a predetermined location and configured to cut a three dimensional volume outside the pipe; and a deployment device configured to move through the pipe to a predetermined location and configured to deploy material in the three dimensional volume.

[0047] The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for the purposes of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings. [Brief explanation of the drawings]

[0048] [Figure 1] FIG. 1 is a partial cross-sectional perspective view of a flexible drill arm for rough cutting a three-dimensional volume from a pipe. [Figure 2] 2 is a partial cross-sectional perspective view of a flexible drill arm for precision cutting the three-dimensional volume of FIG. 1 from a pipe. FIG. [Figure 3] FIG. 1 is a partial cross-sectional perspective view of the tunneling area. [Figure 4] FIG. 4 is a partial cross-sectional perspective view of the area of ​​FIG. 3 immediately prior to the excavation of the tunnel. [Figure 5] FIG. 5 is a partial cross-sectional perspective view of the tunnel of FIGS. 3 and 4 fully excavated. [Figure 6] 1 illustrates an arch structure that can be constructed by the methods and systems described herein. [Figure 7] 10 illustrates an alternative arch structure that can be constructed by the methods and systems described herein. [Figure 8] 10 illustrates a further alternative arch structure that can be constructed by the methods and systems described herein. DETAILED DESCRIPTION OF THE INVENTION

[0049] While the present invention will be described with reference to certain drawings, the present invention is not limited to those drawings but only by the claims. The drawings described are merely schematic and non-limiting. Each drawing may not include all features of the present invention and therefore should not necessarily be considered an embodiment of the present invention. The drawings may exaggerate the size of some of the elements and may not be drawn to scale for illustrative purposes. The dimensions and relative dimensions do not correspond to actual scale consistent with practicing the present invention.

[0050] Furthermore, terms such as "first," "second," "third," etc. in the specification and claims are used to distinguish between similar elements and not necessarily to describe order, whether temporally, spatially, in a sequential order, or in any other manner. It is to be understood that terms so used are interchangeable under appropriate circumstances and that operations are possible in orders other than those described or shown herein. Similarly, method steps described or claimed in a particular order may be understood to be performed in a different order.

[0051] Furthermore, terms such as "top," "bottom," "above," "below," and the like in the specification and claims are used for descriptive purposes and not necessarily to describe relative positions, with the understanding that terms so used are interchangeable under appropriate circumstances and that operation is possible in orientations other than those described or shown herein.

[0052] It should be noted that the term "comprising" used in the claims should not be interpreted as being limited to the means listed below, nor should it exclude other elements or steps. Thus, it should be interpreted as specifying the presence of the stated features, integers, steps, or components as referred to, but not excluding the presence or addition of one or more other features, integers, steps, or components, or groups thereof. Thus, the scope of the phrase "a device comprising means A and means B" should not be limited to a device consisting only of components A and B. In the context of the present invention, this means that the relevant components of the device are only A and B.

[0053] Similarly, it should be noted that the term "connected" as used in the specification should not be construed as being limited to only direct connections. Thus, the scope of the phrase "device A connected to device B" should not be limited to devices or systems in which the output of device A is directly connected to the input of device B. It means that there is a path between the output of A and the input of B, which may be a path that includes other devices or means. "Connected" can mean that two or more elements are in either direct physical or electrical contact, or that two or more elements are not in direct contact with each other but still cooperate or interact with each other. For example, wireless connections are contemplated.

[0054] References throughout this specification to an "embodiment" or "aspect" mean that a particular feature, structure, or characteristic described in connection with an embodiment or aspect is included in at least one embodiment or aspect of the invention. Thus, appearances of the phrases "in one embodiment," "in an embodiment," or "in an aspect" in various places throughout this specification do not necessarily all refer to the same embodiment or aspect, but may refer to different embodiments or aspects. Furthermore, a particular feature, structure, or characteristic of any one embodiment or aspect of the invention may be combined in any suitable manner with any other particular feature, structure, or characteristic of another embodiment or aspect of the invention, in one or more embodiments or aspects, as would be apparent to one of ordinary skill in the art from this disclosure.

[0055] Similarly, it should be recognized that in the description, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of simplifying the disclosure and facilitating understanding of one or more of the various inventive aspects. However, this method of disclosure should not be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, the description of any individual figure or aspect should not necessarily be considered an embodiment of the invention. Rather, as the following claims reflect, inventive aspects may reside in fewer than all features of a single foregoing disclosed embodiment. Accordingly, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as an independent embodiment of the invention.

[0056] Furthermore, while some embodiments described herein include some features included in other embodiments, combinations of features from different embodiments are meant to be within the scope of the present invention and will form yet further embodiments as understood by those skilled in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0057] In the description provided herein, numerous specific details are set forth. However, it will be understood that embodiments of the present invention may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description.

[0058] In the description of the present invention, unless stated to the contrary, the disclosure of alternative values ​​for the upper or lower limits of an acceptable range of a parameter, together with an indication that one of the values ​​is significantly more preferable than the other, should be construed as information that can be read as indicating that each intermediate value of the parameter lying between the alternative more preferable value and the less preferred value is itself preferred over the less preferred value, and also each intermediate value lying between the less preferred value and the intermediate value.

[0059] The use of the term "at least one" may mean one and only one in certain contexts. The use of the term "any" may mean "all" and / or "each" in certain contexts.

[0060] The principles of the present invention will now be explained with reference to exemplary features and by detailed description of at least one drawing. It will be apparent that other arrangements can be constructed according to the knowledge of those skilled in the art without departing from the basic concepts or technical teachings, and the present invention is limited only by the terms of the appended claims.

[0061] Figure 1 is a partial cross-sectional perspective view of a bore lined with a pipe 101 passing through bedrock 103. Inside the pipe 101 is a moveable carriage 105 from which a flexible drill arm 107 projects through a hole 109 in the side wall of the pipe 101. The pipe 101 is shown to have a double wall.

[0062] The flexible drill arm 107 is provided with a rough cutting head 111 for rough cutting the cavity 113 .

[0063] In this and the following figures, any waste material, scrap, and / or drilling fluids are omitted for clarity.

[0064] FIG. 2 shows a precision cutting head 115 replacing the rough cutting head 111 of FIG. 1, with the cavity 113 of FIG. 1 molded into a predetermined three-dimensional volume 117 .

[0065] 3 is a partial cross-sectional perspective view of a geological region 201 to be tunneled, having an arched cross section 203. A series of line bores 205 run along the path of the tunnel beneath the interior of the arched cross section 203. The figure shows multiple blocks 207 being formed around the periphery of the arched cross section 203. The blocks 207 can be formed simultaneously, with each one separate from each adjacent block 207. This is achieved by cutting the shape of each block 207 from the interior of adjacent pipes 205, which can then be hardened by filling each three-dimensional volume with grout.

[0066] FIG. 4 shows the same area as FIG. 3, with additional blocks 209 formed between existing blocks 207 in substantially the same manner.

[0067] Figure 5 shows the same area as Figures 3 and 4, with the geological material inside the arched section 203 being excavated to remove the bore 205 inside the arched section 203 and form the tunnel 211. By first forming the exterior structure with blocks, the excavation of the tunnel can be accomplished without the need to avoid collapsing tunnel shields or other safety systems.

[0068] Figure 6 shows an arch structure with an existing block 307 and an additional block 309 of a similar shape to that shown in Figures 3-5, except that the structure is formed without a base / floor and has an inwardly curved wall at its bottom.

[0069] Figure 7 shows an alternative arch structure similar to that shown in Figure 6, except that it has existing blocks 407 and additional blocks 409 of more equal proportions.

[0070] Figure 8 shows a further alternative arch structure similar to that shown in Figures 6 and 7, but with an existing block 507 of diamond-shaped exterior profile and an additional block 509 of hourglass-shaped exterior profile, so that the blocks interlock when placed adjacent to one another.

[0071] It should be understood that any combinable array of blocks would be possible whether each of the existing blocks and additional blocks are identical, if the existing blocks are a first shape and the additional blocks are a combinable second shape, or if each block has a unique shape.

Claims

1. 1. A method of constructing an underground structure, comprising: excavating a subsurface bore through bedrock geology; lining the bore with a pipe; moving a cutting device through the pipe to a predetermined location; cutting an outer three-dimensional volume of the pipe using the cutting tool; moving a deployment instrument through the pipe to the predetermined location; deploying a material into the three-dimensional volume using the deployment instrument; A method comprising:

2. 2. The method of constructing an underground structure of claim 1, wherein cutting the three-dimensional volume outside the pipe using the cutting equipment comprises making a rough cut using a rough cutting equipment followed by making a precision cut using a precision cutting equipment.

3. The method further comprises: moving the cutting device to a second predetermined location within the pipe; using the cutting device to cut a second three-dimensional volume outside the pipe adjacent to the first three-dimensional volume; moving the deployment instrument to the second predetermined location; deploying a material into the second three-dimensional volume using the deployment instrument; 3. A method for constructing an underground structure according to claim 1 or 2, comprising:

4. The method of constructing an underground structure according to claim 3 , wherein the first three-dimensional volume and the second three-dimensional volume are configured to interdigitate with each other.

5. Before cutting the three-dimensional volume, moving processing equipment through said pipe to a predetermined location; spreading a treatment material into the bedrock geology; The method for constructing an underground structure according to any one of claims 1 to 4, further comprising:

6. The method may further comprise, before cutting the three-dimensional volume: moving a drilling instrument through the bore along a predetermined path to the predetermined location; creating a hole at least partially through the pipe at the predetermined location using the drilling device; A method for constructing an underground structure according to any one of claims 1 to 5, comprising:

7. The method further comprises:

7. A method of constructing an underground structure as set forth in claim 6, including using said drilling equipment to create a hole at most partially through said pipe at said predetermined location.

8. A method for constructing an underground structure according to any one of claims 1 to 7, wherein the pipe comprises a hole before being inserted into the bore.

9. A method for constructing an underground structure according to any one of claims 1 to 8, further comprising the step of introducing structural reinforcement members and / or sensor devices into said volume before deploying material therein.

10. A system for implementing the method for constructing an underground structure according to any one of claims 1 to 9, a directional drilling rig for drilling a subsurface bore through bedrock geology; a pipe for lining the bore drilled by the directional drilling device; a pipe lining device for lining the bore with the pipe; a cutting device configured to be moved to a predetermined location through the pipe and configured to cut an outer three-dimensional volume of the pipe; a deployment device configured to move the material through the pipe to the predetermined location and configured to deploy the material in the three-dimensional volume; A system comprising:

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