Ultrasonic vibration chemical injection system and ultrasonic vibration chemical injection method

Abstract

The present invention provides an ultrasonic vibration chemical injection system for suitably filling cavities located beneath floors or deep within walls with a suspension-type injection material. [Solution] A chemical injection system for injecting a suspension-type injection material, which is a cement-based chemical solution, to fill a cavity 95 that has formed in the ground beneath a floor 91 made of concrete slabs, for example, comprises a chemical injection rod 20, a chemical supply device 50, an ultrasonic oscillator 61, and an air supply device 62. The chemical injection rod 20 has a transducer 47 inside that generates ultrasonic vibrations by an electrical signal, and injects the suspension-type injection material into the cavity while applying the ultrasonic vibrations generated by the transducer 47. The chemical supply device 50 supplies the suspension-type injection material to the chemical injection rod 20. The ultrasonic oscillator 61 outputs an electrical signal to the transducer 47 that generates ultrasonic vibrations. The air supply device 62 supplies air to cool the transducer 47 when ultrasonic vibrations are generated.

Description

Technical Field

[0001] The present invention relates to an ultrasonic vibration chemical solution injection system and an ultrasonic vibration chemical solution injection method.

Background Art

[0002] Conventionally, as disclosed in Patent Documents 1 to 3, a chemical solution injection device and method for injecting a chemical solution into the ground using ultrasonic vibration are known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the prior arts of Patent Documents 1 and 2, mainly for the purpose of injecting a chemical solution into a relatively wide range of soft ground, a method of penetrating an injection pipe into an existing groove or borehole dug from the ground into the ground is assumed. By applying ultrasonic vibration, the occurrence of split injection is avoided, and smooth and uniform penetration of the solidifying agent is realized. In the prior art of Patent Document 3, at the access shaft of a tunnel excavation work by the shield method, the gushing of groundwater can be prevented by pinpoint chemical solution injection.

[0005] However, Patent Documents 1-3 completely ignore the injection of chemical solutions into cavities located beneath floors or deep within walls. For example, in factories, cavities can develop beneath concrete floors within 5-10 years due to factors such as partial ground subsidence (differential settlement) caused by the extraction of surrounding groundwater or consolidation settlement of soil particles during earthquakes. Furthermore, vibrations transmitted from vehicles passing inside and outside the factory, as well as from other machinery and equipment within the factory, accelerate the consolidation settlement of soil particles, thereby promoting the formation of cavities.

[0006] For example, in a factory where precision machinery such as processing machines or semiconductor manufacturing equipment is installed, minute vibrations generated within the factory can resonate through cavities, potentially affecting the operation of the precision machinery. If the precision machinery does not function correctly and cannot perform to its full potential, the quality of the products manufactured by the precision machinery cannot be guaranteed, and it can also cause the precision machinery to malfunction. Therefore, chemical injection work is necessary to fill the cavities with a chemical solution to stabilize the concrete slab floor. Cement-based suspension-type injection materials are suitable as the chemical solution.

[0007] However, the width of the cavities under the floor caused by differential settlement is not constant, ranging from a few millimeters to tens of centimeters, making it difficult to completely fill the gaps with suspension-type injection material using chemical injection methods that do not utilize ultrasonic vibration. Therefore, a large number of injection holes must be made in the floor.

[0008] Furthermore, since high-pressure injection methods can displace structures and floors, injection must be performed without pressure or using low-pressure injection methods. However, in chemical injection methods that do not use ultrasonic vibration, there is a risk that unfilled cavities may remain, or that the integration of the filled areas with the differentially settled ground may be hindered.

[0009] Such problems arise not only in cavities under factory floors, but also in construction work involving the injection of chemical solutions into cavities under floors or deep within walls (including ceilings) made of concrete, plaster, or soil. The present invention was created in view of these points, and its purpose is to provide an ultrasonic vibration chemical injection system and an ultrasonic vibration chemical injection method for suitably filling cavities under floors or deep within walls with a suspension-type injection material. [Means for solving the problem]

[0010] One aspect of the present invention is a chemical injection system for injecting a suspension-type injection material, which is a cement-based chemical solution, into a cavity (95) located beneath a floor (91) or deep within a wall made of concrete, plaster, or soil. The system comprises a chemical injection rod (20), a chemical supply device (50), an ultrasonic oscillator (61), and an air supply device (62).

[0011] The chemical injection rod has a transducer (47) inside that generates ultrasonic vibrations in response to an electrical signal, and injects a suspension-type injection material into the cavity while applying the ultrasonic vibrations generated by the transducer. The chemical supply device supplies the suspension-type injection material to the chemical injection rod. The ultrasonic oscillator outputs an electrical signal to the transducer that generates ultrasonic vibrations. The air supply device supplies air to cool the transducer when ultrasonic vibrations are generated.

[0012] Another aspect of the present invention is a chemical grouting method in which a suspension-type grout material, which is a cement-based chemical, is injected from a chemical grouting rod (20) to fill a cavity (95) located beneath a floor (91) or deep within a wall made of concrete, plaster, or soil. This method includes an installation step (S1), an injection preparation step (S2), and a filling step (S3).

[0013] In the installation process, a chemical supply device (50) that supplies a suspension-type injection material to the chemical injection rod, an ultrasonic oscillator (61) that outputs an electrical signal to generate ultrasonic vibrations to a transducer (47) located inside the chemical injection rod, and an air supply device (62) that supplies air to cool the transducer are installed. In the injection preparation process, the tip of the chemical injection rod is connected to one of several injection holes (92) formed in the floor or wall.

[0014] In the filling process, the transducer is cooled with air supplied from an air supply device, and ultrasonic vibrations are applied by the transducer while a chemical injection rod injects a suspension-type injection material through the injection hole to fill the cavity.

[0015] The system and method of the present invention enable the suitable filling of cavities with a suspension-type grout material in chemical grouting work into cavities located under floors or deep within walls, which were not addressed in Patent Documents 1 to 3. Specifically, since the chemical grouting rod injects the suspension-type grout material while applying ultrasonic vibrations, it becomes possible to fill cavities as small as a few millimeters, and the number of injection holes can be reduced compared to chemical grouting methods that do not use ultrasonic vibrations. Furthermore, even with filling without pressure or using a low-pressure method, the ultrasonic vibration effect enables uniform filling into fine details, so that no unfilled cavities are left behind, and the filled areas can be integrated with the differentially settled ground.

[0016] In a more preferred chemical injection system, the chemical supply device can switch between and supply multiple types of suspension-type injection materials with different curing times. In a corresponding preferred chemical injection method, a target area (GA) for filling, including cavities that are the filling target for the suspension-type injection material, is set, and the filling process includes a contact filling process (S31) and a main filling process (S32).

[0017] In the contact filling process, a first suspension-type injection material (C1) is filled into an area-outside communication section (96) that extends in a direction different from the direction from the injection hole toward the cavity to be filled and communicates with the area to be filled. After the first suspension-type injection material filled into the area-outside communication section has hardened, in this filling process, a second suspension-type injection material (C2), which has a longer hardening time than the first suspension-type injection material, is filled into the cavity to be filled.

[0018] In chemical grouting methods that do not use ultrasonic vibrations, once the injected suspension-type grout starts flowing in a certain direction, it becomes difficult to control. Because it flows out of the area through cavities that form beneath the beams that mark the boundary of the area to be filled, the loss of the suspension-type grout becomes significant.

[0019] On the other hand, in a preferred embodiment of the present invention, for example, by a contact filling step of filling a first suspension-type injection material that cures in units of minutes into the external communication part of the area, a measure for preventing outflow outside the filling planned area is taken. Then, for example, a main filling step of filling a second suspension-type injection material that cures in units of several hours to one day into the cavity to be filled is performed. Thereby, it becomes possible to suppress the loss of the suspension-type injection material and perform efficient filling.

Brief Description of the Drawings

[0020] [Figure 1] The figure which shows the whole structure of the ultrasonic vibration chemical solution injection system of one Embodiment. [Figure 2] The figure explaining the problem generated by the cavity under the factory floor. [Figure 3] (a) Floor plan view, (b) Floor cross-sectional view explaining the construction problem in the chemical solution injection method of the comparative example. [Figure 4] (a) Floor plan view, (b) Floor cross-sectional view explaining the solution of the problem by the ultrasonic vibration chemical solution injection method of one Embodiment. [Figure 5] The flowchart of the ultrasonic vibration chemical solution injection method of one Embodiment.

Mode for Carrying Out the Invention

[0021] <One Embodiment> The ultrasonic vibration chemical solution injection system and the ultrasonic vibration chemical solution injection method of one Embodiment will be described based on the drawings. The system and method of the present invention are a system and method for injecting a suspension-type injection material, which is a cement-based chemical solution, so as to fill a cavity under a floor or behind a wall made of concrete, wall soil or soil. In one embodiment, as a typical construction example, a system and method for injecting a suspension-type injection material into a cavity generated in the ground under a floor made of concrete slabs will be described.

[0022] Figure 1 shows the overall configuration of an ultrasonic vibration chemical injection system 100 according to one embodiment. The ultrasonic vibration chemical injection system 100 is installed in a part of the floor 91 made of concrete slabs inside the factory. In this area, a cavity 95 has been created in the ground beneath the floor due to partial ground subsidence (differential settlement). Multiple injection holes 92 are formed in the floor 91 for checking the conditions beneath the floor and for injecting chemicals.

[0023] Detailed explanations of the components of the ultrasonic vibration drug injection system 100 that are common with the system described in Patent Document 3 (Japanese Patent No. 7429912) will be omitted. This ultrasonic vibration drug injection system 100 comprises a drug injection rod 20, a drug supply device 50, an ultrasonic oscillator 61, and an air supply device 62.

[0024] The chemical injection rod 20 consists of an injection hole mounting bracket 30 and a rod body 40. The injection hole mounting bracket 30 is installed on the surface of the floor 91 around the injection hole 92 and the rod is erected approximately vertically on the floor 91 with the bracket facing downwards. The injection hole mounting bracket 30 and the tip of the rod body 40 are connected, for example, by a cam-lock type connector. This connects the tip of the chemical injection rod 20 to the injection hole 92. A handle 49 is provided on the outer surface of the rod body 40. A chemical suction port 43 and an air supply / exhaust port 45 are provided on the base end of the rod body 40.

[0025] A transducer 47, which generates ultrasonic vibrations by an electrical signal, is provided inside the tip of the rod body 40. The configuration of the transducer 47 and the configuration related to the air supply for cooling the transducer 47 are the same as the configuration disclosed in Patent Document 3. The frequency of the ultrasonic waves generated by the transducer 47 is, for example, 28 kHz, and the output of the ultrasonic waves is, for example, 10 W to 100 W.

[0026] The chemical supply device 50 includes a mixer and a pump, and supplies a suspension-type injection material, which is a cement-based chemical solution, from the pump to the chemical injection rod 20. The pump of the chemical supply device 50 and the chemical suction port 43 of the rod body 40 are connected by a hose. Furthermore, the chemical supply device 50 of this embodiment can switch and supply multiple types of suspension-type injection materials with different curing times.

[0027] For example, if two types of suspension-type injection materials are used in the contact filling process and the main filling process, as described later, the chemical supply device 50 may be equipped with two sets of mixers and pumps, and the chemical may be supplied to the chemical injection rod 20's chemical injection port 43 (Figure 1 shows two chemical injection ports 43 on the chemical injection rod 20) via separate hoses. Alternatively, a switching valve may be provided in the middle of the path from the two sets of mixers and pumps to the chemical injection rod 20. In that case, only one chemical injection port 43 on the chemical injection rod 20 is needed. Furthermore, if sufficient interval time can be secured between the contact filling process and the main filling process, the injection material for the contact filling process may be discharged using one set of mixers and pumps and then replaced with the injection material for the main filling process.

[0028] The ultrasonic oscillator 61 outputs an electrical signal to the transducer 47 to generate ultrasonic vibrations. The air supply device 62 supplies air to cool the transducer 47 when ultrasonic vibrations are generated. In this embodiment, the ultrasonic oscillator 61 and the air supply device 62 are unitized as an ultrasonic oscillator unit 60.

[0029] As referenced in Patent Document 3, the ultrasonic oscillator unit 60 comprises an ultrasonic oscillator 61 and An air supply system 62, including an air compressor, regulator, and air dryer, is installed as a unit on a common platform. Compressed air used in the factory may be supplied to the chemical injection rod 20 via the air supply system 62. The electrical signal output by the ultrasonic oscillator 61 is sent to the transducer 47 via an electrical cable. In a preferred configuration, the electrical cable is inserted inside the air tube that supplies air from the air supply system 62 to the rod body 40.

[0030] With the above configuration, the chemical injection rod 20 injects the suspension-type injection material into the cavity 95 while applying ultrasonic vibrations generated by the transducer 47. As a result, ultrasonic vibration energy is applied to the particles and medium contained in the injection material, as well as to the soil particles, water, and air in the ground, improving the penetration and diffusion effect of the suspension-type injection material. Therefore, the suspension-type injection material can be effectively penetrated even into cavities of several millimeters in size.

[0031] Next, referring to Figure 2, we will explain the problems caused by cavities under the factory floor. In the situation shown in Figure 2, a cavity 95 exists beneath the concrete floor 91 on which precision machinery M, such as processing machines and semiconductor manufacturing equipment, is installed. In this situation, if minute vibrations generated within the factory resonate through the cavity 95, it may affect the operation of the precision machinery M. If the precision machinery M does not operate correctly and cannot perform to its full potential, the quality of the products produced by the precision machinery M cannot be guaranteed, and it may also cause the precision machinery M to malfunction.

[0032] Cavities beneath factory floors typically develop within 5 to 10 years due to factors such as partial ground subsidence (differential settlement) caused by the extraction of surrounding groundwater and soil consolidation settlement during earthquakes. Furthermore, vibrations transmitted from vehicles passing inside and outside the factory, as well as from other machinery and equipment within the factory, accelerate soil consolidation settlement, thus promoting the formation of cavities.

[0033] Therefore, chemical grouting is necessary to fill the cavities with a chemical solution to stabilize the concrete slab floor. A cement-based suspension-type grout is suitable as the chemical solution. However, conventional chemical grouting methods that do not use ultrasonic vibration (hereinafter referred to as "comparative example") had construction challenges. Referring to Figure 3, the construction challenges of the comparative example chemical grouting method will be explained.

[0034] As shown in the floor plan in Figure 3(a), beams 94 are provided between four columns 93 arranged in a grid pattern, and a rectangular section (for example, about 8m x 4m) enclosed by the beams 94 is set as the area GA to be filled. Multiple injection holes 92 are formed in the floor 91 within the area GA to be filled. The injection holes 92 are used as confirmation holes to understand the conditions under the floor and as holes for injecting the chemical solution. Rods 82 of a similar diameter are connected to the injection holes 92. The suspension-type injection material C is injected into the injection holes 92 via the hose 81 and rod 82.

[0035] In Figure 3(a), a suspension-type injection material C is injected from the injection hole 92 in the upper right corner of the page in the area GA to be filled, toward the cavity 95 that is the target of filling. As shown in Figure 3(b), the injection material C also flows outside the area GA to be filled through the cavity that has formed beneath the beam 94. The path that extends in a direction different from the direction toward the cavity 95 that is the target of filling and communicates with the outside of the area GA to be filled is referred to as the "outside communication section 96".

[0036] (Construction challenge 1 of the comparative example) The width of the cavity 95 that forms beneath the floor 91 due to differential settlement is not constant, ranging from a few millimeters to several tens of centimeters. In the comparative example's chemical injection method, which does not use ultrasonic vibration, it is difficult to fill the gaps completely with the suspension-type injection material C. Therefore, a large number of injection holes 92 are required in the floor 91 (11 in the illustrated example).

[0037] (Construction challenge 2 of the comparative example) Because using a high-pressure pressurized method for filling with chemical solutions can displace structures and floors, it is necessary to fill them using a no-pressure or low-pressure pressurized method. However, in the comparative example of a chemical injection method that does not use ultrasonic vibration, there is a risk that unfilled cavities will remain, or that the integration of the filled portion with the differentially settled ground will be hindered.

[0038] (Construction challenge 3 of the comparative example) In the comparative example of the chemical grouting method that does not use ultrasonic vibration, once the injected suspension-type grout material C begins to flow in a certain direction, it becomes difficult to control. Because it flows out to the area outside the area connecting section 96 through a cavity that forms beneath the beam 94 which is the boundary of the area to be filled GA, the loss of the suspension-type grout material C becomes significant.

[0039] Next, referring to Figure 4, we will explain how the ultrasonic vibration chemical injection method of one embodiment solves the construction problems of the comparative example. In this embodiment, two types of suspension-type injection materials C1 and C2 with different curing times are injected in stages. In this embodiment, compared to the chemical injection method of the comparative example which does not use ultrasonic vibration, the suspension-type injection materials C1 and C2 can be suitably filled into the cavity 95 beneath the floor 91.

[0040] (Problem Solving 1) In this embodiment, the drug injection rod 20 injects the suspension-type injection materials C1 and C2 while applying ultrasonic vibrations, making it possible to fill cavities 95 that are several millimeters in size, and reducing the number of injection holes 92 compared to the comparative example (8 in the illustrated example).

[0041] (Problem Solving 2) In this embodiment, even with no pressure or low-pressure pressure filling, the ultrasonic vibration effect enables uniform filling into fine details, thus eliminating unfilled cavities and integrating the filled portion with the differentially settled ground.

[0042] (Problem Solving 3) In this embodiment, a contact filling step is performed in which a first suspension-type injection material C1, which hardens in, for example, a few minutes, is filled into the area-outside communication section 96 to prevent outflow outside the area GA to be filled. Subsequently, the main filling step is performed in which a second suspension-type injection material C2, which hardens in, for example, several hours to a day, is filled into the cavity 95 to be filled. Each step will be described later from a chronological perspective with reference to the flowchart in Figure 5. This makes it possible to suppress the loss of the suspension-type injection material and perform efficient filling.

[0043] Next, with reference to the flowchart in Figure 5, an ultrasonic vibration chemical injection method of one embodiment will be described. In the flowchart, the symbol "S" represents a step. In the installation process of S1, the devices and equipment constituting the ultrasonic vibration chemical injection system 100 are brought in, and a temporary plant is erected around the construction site. The devices constituting the system 100 include a chemical supply device 50, an ultrasonic oscillator 61, and an air supply device 62.

[0044] In the injection preparation process of S2, the worker installs the injection hole mounting bracket 30 into one of the multiple injection holes 92 formed in the floor 91 and connects it to the rod body 40, thereby connecting the tip of the chemical injection rod 20 to the injection hole 92.

[0045] In the filling process of S3, the transducer 47 is cooled with air supplied from the air supply device 62, and ultrasonic vibrations are applied by the transducer 47, while the chemical injection rod 20 injects a suspension-type injection material through the injection hole 92 to fill the cavity 95. Specifically, the filling process S3 includes the contact filling process S31 and the main filling process S32.

[0046] In the contact filling process S31, the area-outside communication section 96 (see Figure 4) is filled with a first suspension-type injection material C1 that hardens in a matter of minutes. As the first suspension-type injection material C1 filled in the area-outside communication section 96 hardens, measures are taken to prevent the injection material from flowing out of the area GA where it is to be filled. Subsequently, in the main filling process S32, the second suspension-type injection material C2 is filled into the cavity 95 that is the filling target. The second suspension-type injection material C2 has a longer hardening time than the first suspension-type injection material C1, hardening in a matter of hours to a day.

[0047] In this way, by using two types of suspension-type injection materials C1 and C2 with different curing times, and performing the main filling process S32 after the outflow prevention treatment in the contact filling process S31, the loss of the suspension-type injection material can be suppressed.

[0048] Once the injection of suspension-type injection materials C1 and C2 is complete through one injection hole 92, the supply of chemical solution from the chemical solution supply device 50, the supply of air from the air supply device 62, and the output of electrical signals from the ultrasonic oscillator 61 are stopped. When replacing injection materials C1 and C2 and when injection is complete, any injection material remaining in the chemical solution injection rod 20 is washed away with high-pressure water.

[0049] In S4, the status of the injection material filling below the unused injection hole 92 is checked, and if there are any unfilled areas remaining, it is determined whether it is necessary to inject the chemical solution into the other injection holes 92. If it is determined that injection into the other injection holes 92 is necessary (S4: YES), S2 and S3 are repeated. However, if the injection hole 92 is not adjacent to the area-outside communication section 96, or if measures to prevent outflow in each direction have been completed, the contact filling process S31 may be omitted, and only the filling process S32 may be performed.

[0050] Once the suspension-type injection material has been filled into the subfloor of the area GA to be filled, and it is determined that no further injection into other injection holes 92 is necessary (S4:NO), the plant is removed in S5. This concludes the ultrasonic vibration chemical injection method of this embodiment.

[0051] <Other Embodiments> (1) The shape of the area GA to be filled is not limited to a simple rectangle as illustrated in Figures 3 and 4, but may be a multi-tiered rectangle, a trapezoid, etc., depending on the layout of the factory.

[0052] (2) In the above embodiment, two types of suspension-type injection materials with different curing times are supplied in the contact filling step S31 and the main filling step S32, but three or more types of suspension-type injection materials may be supplied in a switchable manner depending on the characteristics of the ground, etc.

[0053] (3) The ultrasonic vibration chemical injection system and method of the present invention can be applied not only to cavities under factory floors made of concrete slabs, but also to cavities under floors or behind walls made of concrete, plaster, or soil. "Walls" include vertical walls, inclined walls (slope surfaces), ceilings, etc. By using ultrasonic vibrations to inject chemicals into cavities behind these walls, suspension-type injection materials can be suitably penetrated even into cavities of several millimeters in size.

[0054] The present invention is not limited in any way to the embodiments described above, and can be implemented in various forms without departing from its spirit. [Explanation of symbols]

[0055] 100... Ultrasonic vibration drug injection system, 20...Medication injection rod, 47. Transducer, 50... Chemical solution supply device, 61. Ultrasonic oscillator, 62. Air supply device, 91...floor, 92...injection hole, 95...cavity, C1, C2... Suspension-type injection material; GA... Area to be filled.

Claims

1. A chemical injection system for injecting a suspension-type injection material, which is a cement-based chemical solution, to fill a cavity (95) located beneath a floor (91) made of concrete, plaster, or soil, or deep within a wall, A transducer (47) that generates ultrasonic vibrations by an electrical signal is provided inside, and a chemical injection rod (20) that injects a suspension-type injection material into the cavity while applying the ultrasonic vibrations generated by the transducer, A chemical supply device (50) that supplies a suspension-type injection material to the chemical injection rod, The transducer is equipped with an ultrasonic oscillator (61) that outputs an electrical signal to generate ultrasonic vibrations, An air supply device (62) that supplies air to cool the transducer when ultrasonic vibrations are generated, An ultrasonic vibration drug injection system equipped with [unspecified feature].

2. The ultrasonic vibration drug injection system according to claim 1, wherein the drug supply device is capable of switching and supplying multiple types of suspension-type injection materials with different curing times.

3. A chemical grouting method in which a suspension-type grout material, which is a cement-based chemical, is injected from a chemical grouting rod (20) to fill a cavity (95) located beneath a floor (91) made of concrete, plaster, or soil, or deep inside a wall, Installation step (S1) includes installing a chemical supply device (50) that supplies a suspension-type injection material to the chemical injection rod, an ultrasonic oscillator (61) that outputs an electrical signal to generate ultrasonic vibrations to a transducer (47) provided inside the chemical injection rod, and an air supply device (62) that supplies air to cool the transducer. An injection preparation step (S2) is to connect the tip of the chemical injection rod to one of the multiple injection holes (92) formed in the floor or the wall, A filling step (S3) is performed in which the transducer is cooled with air supplied from the air supply device, ultrasonic vibrations are applied by the transducer, and the chemical injection rod injects a suspension-type injection material through the injection hole to fill the cavity, An ultrasonic vibration chemical injection method.

4. A filling area (GA) including the aforementioned cavity, which is the target for filling with the suspension-type injection material, has been set. The aforementioned filling process is A contact filling step (S31) in which a first suspension-type injection material (C1) is filled into an area-outside communication section (96) that extends in a direction different from the direction toward the cavity of the filling target from the injection hole and communicates with the area outside the area to be filled, After the first suspension-type injection material filled in the area outside the communication section has hardened, the main filling step (S32) involves filling the cavity of the filling target with a second suspension-type injection material (C2) which has a longer hardening time than the first suspension-type injection material. The ultrasonic vibration chemical injection method according to claim 3, including the following:

Images