Invert mold manufacturing apparatus, invert construction system, and invert construction method

Abstract

To propose an invert mold manufacturing device capable of reducing manpower required for construction while reducing trouble of construction related to a construction of an invert of a tunnel, an invert construction system and an invert construction method.SOLUTION: A mold for an invert is manufactured by utilizing an invert mold manufacturing device 2 including a pair of fixed beams 21, 21 provided at an upper part of a tunnel bedding surface at an interval, a movable beam 22 movably and horizontally stretched along the pair of fixed beams 21, 21, a nozzle 23 movably provided along the movable beam 22 and fixing material supply means 24 for supplying a fixing material to the nozzle 23.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to an invert formwork manufacturing apparatus, an invert construction system, and an invert construction method.

Background Art

[0002] In mountain tunnels (such as NATM), the standard support pattern changes according to the ground classification, resulting in sections with an invert and sections without an invert. Fig. 1 shows a tunnel T with an invert. In sections with an invert, the joint (hunch part C3) between the covering concrete C1 and the invert concrete C2 is generally formed in a cross-sectional curve shape. Such a cross-sectional curve-shaped hunch part C3 (the upper end part of the invert) is constructed using an invert formwork whose surface (the surface on the concrete side) is formed in a curved shape (see, for example, Patent Document 1). Also, for the construction of the invert, it is common to perform the construction in left and right half-sections in order to secure a passage from the portal to the face. Therefore, for the construction of the invert, formworks such as a backing formwork, a longitudinal formwork, and an invert formwork are assembled on the floor surface Ts formed by excavation, and then concrete is placed. Such construction of the invert requires a plurality of workers. Also, the assembly of the formworks is generally performed manually, which is time-consuming.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] From such a perspective, the present invention aims to propose an invert formwork manufacturing apparatus, an invert construction system, and an invert construction method for tunnel invert construction, which reduce the labor of construction and enable reduction of the number of personnel required for construction.

Means for Solving the Problems

[0005] To solve the above problems, the invert formwork manufacturing apparatus of the present invention manufactures a formwork for invert by discharging a solidifying material onto the tunnel bedding surface, and includes a pair of fixed beams provided at an interval above the tunnel bedding surface, a movable beam horizontally mounted movably along the pair of fixed beams, a nozzle provided movably along the movable beam, and a solidifying material supply means for supplying the solidifying material to the nozzle. Further, the invert construction method of the present invention includes a step of excavating the bottom of the tunnel and performing bedding, a step of installing the invert formwork manufacturing apparatus, a step of discharging the solidifying material using the invert formwork manufacturing apparatus to form a transverse formwork and a longitudinal formwork, and a step of placing concrete in the space surrounded by the transverse formwork and the longitudinal formwork. In such an invert construction method, in addition to the invert formwork manufacturing apparatus, it is desirable to use an invert construction system including a placing movable beam horizontally mounted movably along the pair of fixed beams, a plurality of placing hoses provided on the placing movable beam, and a concrete supply means for supplying concrete to the placing hoses.

[0006] According to such an invert formwork manufacturing apparatus and an invert construction method, since the formwork is formed by discharging the solidifying material from a nozzle that moves back and forth, left and right, it is simpler than the case of assembling the formwork manually. Therefore, it is possible to reduce the number of workers. Incidentally, the invert formwork manufacturing apparatus may further include a 3D scanner movably provided along the movable beam. When the invert formwork manufacturing apparatus includes a 3D scanner, a step of scanning the invert floor surface using the 3D scanner and a step of calculating the difference between the shape of the invert floor surface and the design cross-section may be performed, and the solidifying material may be discharged according to the difference to form a transverse formwork and a longitudinal formwork. By doing so, a formwork according to the shape of the site can be easily formed.

Advantages of the Invention

[0007] According to the invert formwork manufacturing apparatus, invert construction system, and invert construction method of the present invention, in the construction of the invert of a tunnel, it is possible to reduce the labor of construction and reduce the number of personnel required for construction.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

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Figure 8

Figure 9

Figure 10

Embodiments for Carrying Out the Invention

[0009] In this embodiment, a method for constructing an invert in a tunnel T having an invert will be described (see FIG. 1). In this embodiment, an invert formwork is formed using an invert construction system 1, and the invert is formed by placing concrete in this formwork. The formwork is formed using a so-called 3D printer. The invert construction system 1 includes an invert formwork manufacturing device 2 (FIGS. 2 to 4) and a concrete placing device 3 (FIGS. 5 to 7). The invert formwork manufacturing device 2 is a device that manufactures an invert formwork on the floor surface by discharging a solidifying material onto the tunnel floor surface Ts. FIGS. 2 to 4 show an overview of the invert formwork manufacturing device 2. As shown in FIG. 2, the invert formwork manufacturing device 2 includes a pair of fixed beams 21, 21, a movable beam 22, a nozzle 23, a solidifying material supply means 24, and a 3D scanner 25.

[0010] As shown in FIGS. 2 and 3, a pair of fixed beams 21, 21 are provided at intervals on the left and right above the tunnel floor surface Ts. The pair of fixed beams 21, 21 constitute a part of a gantry for supporting the nozzles 23 and the 3D scanner 25. In the present embodiment, the fixed beams 21 are provided at the tunnel side part and the tunnel central part along the tunnel axis direction (Y direction), respectively. The fixed beam 21 is made of steel material (H-shaped steel in the present embodiment). The fixed beam 21 provided at the tunnel central part is supported by columns 21a, 21a made of steel material (for example, H-shaped steel or channel steel) erected on the tunnel floor surface Ts, as shown in FIGS. 3 and 4. In the present embodiment, the columns 21a are provided at both ends of the fixed beam 21, respectively. Steel material (for example, channel material) is fixed to the columns 21a, 21a arranged at the end in the tunnel axis direction as support members (brackets) 21b, and the fixed beam 21 is fixed on the support member 21b. Further, the fixed beam 21 provided at the tunnel side part (the right side in FIG. 3) is supported by a support member (bracket) 21c (for example, channel steel) fixed to the support and protection work. As shown in FIG. 3, the fixed beams 21, 21 provided on the left and right are provided at the same height. Further, the fixed beams 21, 21 arranged on the left and right are connected by connecting members 21d, 21d made of steel material (for example, angle material) horizontally mounted at both ends. That is, a gantry is formed by combining the fixed beam 21, the column 21a, the support members 21b, 21c, and the connecting members 21d, 21d.

[0011] As shown in FIG. 3, the movable beam 22 is horizontally mounted on the pair of fixed beams 21, 21. The movable beam 22 is movable along the pair of fixed beams 21, 21. That is, the movable beam 22 is movable along the tunnel axis direction (Y direction). The movable beam 22 is made of steel material such as H-shaped steel, and is horizontally mounted on the fixed beams 21, 21 via moving means (not shown) such as traveling wheels and rollers that travel on the fixed beams 21, 21. In the present embodiment, the end of the movable beam 22 is inserted between the upper and lower flanges of the fixed beam 21 together with the moving means. The movement of the movable beam 22 in the tunnel axis direction is controlled by control means (not shown).

[0012] The nozzle 23 is provided on the movable beam 22. The nozzle 23 is movable along the movable beam 22. That is, the nozzle 23 moves in the tunnel transverse direction (X direction) along the movable beam 22 and moves in the tunnel axis direction (Y direction) together with the movable beam 22, so that it can move over the entire construction range in plan view. Further, the nozzle 23 is provided so as to be movable in the vertical direction (Z direction) with respect to the movable beam 22. The nozzle 23 of the present embodiment is configured to be movable by moving means (not shown) such as traveling wheels or rollers that travel along the flange of the movable beam 22. The movement of the nozzle 23 in the tunnel transverse direction (movement along the movable beam 22) and the movement in the vertical direction are controlled by a control means (not shown). A solidifying material hose 26 extending from the solidifying material supply means 24 is connected to the nozzle 23. The nozzle 23 discharges the solidifying material transported through the solidifying material hose 26 toward the floor surface.

[0013] The solidifying material supply means 24 supplies the solidifying material to the nozzle 23 through the solidifying material hose 26. The solidifying material is made of, for example, a hydraulic material such as mortar or concrete. The solidifying material supply means 24 includes a hopper 24a and a concrete pump 24b. The solidifying material transported through the adit vehicle and charged into the hopper 24a is pumped by the concrete pump 24b through the solidifying material hose 26 to the nozzle 23. The solidifying material hose 26 of the present embodiment is extended in the tunnel axis direction (Y direction) at the upper part of the tunnel through a pulley 26a provided at the upper part of the tunnel and then connected to the nozzle 23.

[0014] The 3D scanner 25 is provided on the movable beam 22 so as to be movable along the movable beam 22. The 3D scanner 25 of the present embodiment is integrated with or attached to the nozzle 23 and, together with the nozzle 23, can move in the tunnel transverse direction (X direction) along the movable beam 22 and can move in the tunnel axis direction (Y direction) together with the movable beam 22. The measurement result by the 3D scanner 25 is transmitted to a terminal (not shown) such as a computer, a tablet, or a smartphone.

[0015] The concrete placing device 3 places concrete into the formwork formed by the inverted formwork manufacturing device 2. The concrete placing device 3 is shown in FIGS. 5 to 7. As shown in FIG. 5, the concrete placing device 3 includes a placing movable beam 31, a placing hose 32, a concrete supply means 33, and a vibrator 34. As shown in FIGS. 5 and 6, the placing movable beam 31 is horizontally mounted on a pair of fixed beams 21, 21 so as to be movable along the pair of fixed beams 21, 21. That is, the placing movable beam 31 is movable along the tunnel axis direction (Y direction). The placing movable beam 31 is made of a steel material such as H-shaped steel and is horizontally mounted on the fixed beams 21, 21 via moving means (not shown) such as traveling wheels or rollers that travel on the fixed beams 21, 21. In the present embodiment, the end of the placing movable beam 31 is inserted between the upper and lower flanges of the fixed beam 21. The movement of the placing movable beam 31 in the tunnel axis direction may be automatically performed via a control means or may be manually performed. The placing movable beam 31 of the present embodiment is provided separately from the movable beam 22 for formwork construction and is disposed on the shaft mouth side of the movable beam 22, but the placing movable beam 31 may be provided on the face side of the movable beam 22.

[0016] As shown in FIGS. 5 and 6, the placing hose 32 is provided on the placing movable beam 31. In the present embodiment, a plurality of placing hoses 32, 32,... are provided on the placing movable beam 31 at arbitrary intervals. The placing hose 32 is suspended from the placing movable beam 31. A concrete hose 35 extending from the concrete supply means 33 is connected to the placing hose 32. Further, in the present embodiment, a plurality of vibrators 34, 34,... are provided on the placing movable beam 31.

[0017] As shown in FIGS. 5 and 7, the concrete supply means 33 supplies the concrete transported by an agitator truck or the like to a plurality of placing hoses 32, 32,... via a concrete hose 35. The concrete supply means 33 comprises a concrete pump. The concrete transported into the tunnel is pressure-fed by the concrete supply means 33 (concrete pump) via the concrete hose 35 to the placing hose 32 and poured into the formwork 4 (the space surrounded by the transverse formwork 41 and the longitudinal formwork 42). The concrete hose 35 is connected to the placing hose 32 via a valve (not shown).

[0018] Next, a method for constructing an invert using the invert construction system 1 will be described. FIG. 8 shows the procedure of the invert construction method. As shown in FIG. 8, the invert construction method includes a bedding step S1, a device installation step S2, a scanning step S3, an error calculation step S4, a formwork forming step S5, a placing step S6, and a haunch portion construction step S7. In this embodiment, the invert is constructed one side at a time in terms of the tunnel cross-section, and the construction is carried out in sections of 10.5 m in the tunnel axis direction. FIG. 9 shows the bedding step S1. The bedding step S1 is a step of excavating the bottom of the tunnel to perform bedding (forming the tunnel bedding surface Ts). The excavation of the bottom of the tunnel is carried out using an excavator such as a backhoe. The excavated soil is carried out using a transport means such as a truck or a belt conveyor. A slope S with a predetermined gradient is formed at the end of the construction range (excavation range).

[0019] The device installation step S2 is a step of installing the invert construction system 1 (see FIGS. 2 to 4). First, the fixed beams 21, 21 are installed. In the device installation step S2, first, a support column 21a is erected at the center of the tunnel, and support members 21b, 21c are installed on the support column 21a and the side portion of the tunnel. Next, the fixed beam 21 is fixed to the support members 21b, 21c. Subsequently, a movable beam 22 is horizontally mounted on the fixed beams 21, 21, and a nozzle 23 and a 3D scanner 25 are installed on the movable beam 22. Further, a placing movable beam 31 is horizontally mounted on the fixed beams 21, 21, and placing hoses 32, 32,... are installed on the placing movable beam 31.

[0020] The scanning step S3 is a step of scanning the tunnel floor surface. The scanning of the tunnel floor surface is performed by the 3D scanner 25 of the invert formwork manufacturing apparatus 2. By moving the 3D scanner 25 along the movable beam 22, it is moved in the tunnel transverse direction, and by moving the movable beam 22 along the fixed beams 21, 21, the 3D scanner 25 is moved in the tunnel longitudinal direction. By doing so, the measurement (scan) of the entire construction range of the invert is performed. The measurement result is transmitted to a computer or the like. At this time, the placing movable beam 31 is arranged at the shaft side end of the fixed beam 21. The error calculation step S4 is a step of redesigning the formwork shape according to the actual site conditions. In the redesign step, the difference (construction error) between the shape of the tunnel floor surface measured by the 3D scanner 25 and the design cross-section is calculated, and the discharge amount of the solidifying material (height of the formwork) according to the actual site conditions is calculated. Then, the movement route (XYZ coordinates) of the nozzle 23 is set so that a formwork can be formed according to the position of the upper surface of the invert in the design.

[0021] The formwork forming step S5 is a step of forming the formwork 4 on the floor surface. To form the formwork, an inverted formwork manufacturing apparatus 2 is used. In this embodiment, a plurality of transverse formworks (including the edge formworks) 41, 41,... are formed at intervals in the longitudinal direction of the tunnel, and a plurality of longitudinal formworks 42, 42,... are formed at intervals in the transverse direction of the tunnel, thereby constructing the grid-shaped formwork 4. The construction of the transverse formwork 41 is performed by discharging the solidifying material while moving the nozzle 23 along the movable beam 22 after arranging the movable beam 22 at a predetermined position. By reciprocating the nozzle 23 a plurality of times, the solidifying material is laminated to a predetermined height. The end portion of the transverse formwork 41 on the tunnel wall side has a curved surface shape according to the shape of the side portion of the invert. The construction of the longitudinal formwork 42 is performed by discharging the solidifying material while moving the movable beam 22 along the fixed beam 21 with the nozzle 23 arranged at a predetermined position of the movable beam 22. By reciprocating the movable beam 22 (nozzle 23) a plurality of times, the solidifying material is laminated to a predetermined height. After constructing the transverse formwork 41 and the longitudinal formwork 42, curing is performed until a predetermined strength is developed.

[0022] The placing step S6 is a step of placing concrete in the space surrounded by the transverse formwork 41 and the longitudinal formwork 42 (see FIGS. 5 to 7). To place the concrete, a concrete placing apparatus 3 is used. The concrete is placed by flowing the concrete from the placing hoses 32, 32,... while arranging the placing movable beam 31 near the middle between adjacent transverse formworks 41. At this time, the movable beam 22 for formwork construction is arranged at the end portion on the face side of the fixed beam 21. As the concrete is poured, the placed concrete is compacted using the vibrator 34. The placing hoses 32 and the vibrator 34 are arranged at positions corresponding to between adjacent longitudinal formworks 42. After flowing the concrete to a predetermined height and compacting it, the placing movable beam 31 is moved and the concrete is poured again. After flowing a predetermined amount of concrete into the formwork 4, the surface of the concrete is leveled along the upper surface of the formwork 4 to finish the surface of the invert.

[0023] The haunch forming process S7 is a process of constructing the wall side end portion (haunch portion 5) of the invert that exhibits a curved surface shape. The haunch forming process S7 is shown in FIG. 10. As shown in FIG. 10, in the present embodiment, the haunch portion 5 is formed using the invert formwork manufacturing apparatus 2. The formation of the haunch portion 5 is performed by discharging the solidifying material from the nozzle 23 while moving the movable beam 22 along the fixed beam 21 or moving the nozzle 23 along the movable beam 22 with the nozzle 23 disposed at a predetermined position (position corresponding to the haunch portion 5). By reciprocating the nozzle 23 a plurality of times, the solidifying material is laminated to a predetermined height. After laminating the solidifying material to the predetermined height, the nozzle 23 is shifted and the same operation is performed. By repeating the same operation a plurality of times, a haunch portion 5 having a curved surface shape (triangular shape in cross section) is formed. After curing the concrete, perform joint treatment and backfill the invert. As described above, the floor laying process S1 to the haunch forming process S7 are taken as one cycle, and by repeating this along the tunnel axis direction, the invert of the target section is constructed.

[0024] According to the invert construction system 1 and the invert construction method of the present embodiment, since the solidifying material is discharged from the nozzle 23 that moves back and forth in the front, rear, left, and right directions to automatically form the formwork, it is simpler than the case of manually assembling the formwork. Therefore, it is possible to reduce the number of workers. In addition, by scanning the tunnel floor surface with the 3D scanner 25, the formwork 4 according to the on-site situation can be formed by the 3D printer. Also, regarding the curved surface portion of the side portion (haunch portion) of the invert, it can be formed in a curved surface shape using a 3D printer. Therefore, a curved surface formwork is not required, the placement state of the concrete can be visually confirmed, and quality defects such as honeycombing and batter are less likely to occur. By limiting the range of use of 3D printing, it is possible to reduce costs and shorten the construction period compared to the case of constructing the entire invert by 3D printing. Since a large-scale device is not required, it can be adopted even in the limited space in the tunnel pit. In addition, detailed construction records can be retained as digital data.

[0025] The present invention is not limited to the foregoing embodiments, and each of the above-described components can be appropriately changed without departing from the spirit of the present invention. For example, the configuration of the gantry that supports the movable beam 22 and the placing movable beam 31 is not limited to the structure shown in the foregoing embodiment. For example, in the foregoing embodiment, the fixed beam 21 disposed on the side is supported by the shoring work, but the fixed beam 21 on the side may be supported by a column. In addition, in the foregoing embodiment, the invert construction is performed one side at a time, but when the cross-sectional shape of the tunnel is small, the entire width may be constructed simultaneously. In addition, the concrete placing device may be used as necessary. That is, the concrete may be placed by a method similar to the conventional construction method. When using high-fluidity concrete, tamping by a vibrator can be omitted. In the foregoing embodiment, the case where the invert formwork manufacturing apparatus 2 includes the 3D scanner 25 has been described, but the 3D scanner 25 may be omitted. In this case, the scanning step S3 and the redesign step S4 are omitted. Note that instead of the scanning step S3, surveying may be performed using an optical distance measuring instrument or the like. The measurement of the bedding surface by the 3D scanner 25 may be performed only at the locations where the transverse formwork 41 and the longitudinal formwork 42 are formed. In addition, instead of the 3D scanner 25, a laser distance meter may be used. When using a laser distance meter, the distance from the laser distance meter to the bedding surface Ts or the upper surface of the solidifying material is measured, and the solidifying material may be discharged according to the measurement result. Note that the method of discharging the solidifying material is not limited. A method of repeatedly stacking layers of a material with high slump and self-supporting properties or a method of thinly stacking a soft material such as shotcrete while applying pressure may also be used. In the above-described embodiment, the haunch portion is formed using a 3D printer. However, the haunch portion may be formed in the same manner as the general portion (the portion other than the inverted haunch portion) by placing concrete in the formwork 4. At this time, the tunnel side wall side end portion of the transverse formwork 41 is formed in a state having a curved surface according to the shape of the haunch portion. Then, the side end portion (haunch portion) of the invert may be formed into a curved surface by leveling the concrete surface along the upper surface of the transverse formwork 41 of the tunnel side wall side end portion having a curved surface shape.

Explanation of Signs

[0026] 1 Invert construction system 2 Invert formwork manufacturing device 21 Fixed beam 22 Movable beam 23 Nozzle 24 Solidifying material supply means 25 3D scanner 3 Concrete placing device 31 Placing movable beam 32 Placing hose 33 Concrete supply means 4 Formwork 41 Transverse formwork 42 Longitudinal formwork

Claims

1. An invert formwork manufacturing apparatus for manufacturing a formwork for invert by discharging a solidifying material onto a tunnel floor surface, comprising: a pair of fixed beams provided at an interval above the tunnel floor surface; a movable beam horizontally mounted movably along the pair of fixed beams; a nozzle provided movably along the movable beam; a solidifying material supply means for supplying a solidifying material to the nozzle. The invert formwork manufacturing apparatus is characterized by the above.

2. The invert formwork manufacturing apparatus according to claim 1, further comprising a 3D scanner provided movably along the movable beam.

3. An invert construction system comprising the invert formwork manufacturing apparatus according to claim 1 or claim 2, and a concrete placing apparatus for placing concrete into the formwork, wherein the concrete placing apparatus comprises: a placing movable beam horizontally mounted movably along the pair of fixed beams; a plurality of placing hoses provided on the placing movable beam; a concrete supply means for supplying concrete to the placing hoses. The invert construction system is characterized by the above.

4. An invert construction method using the invert formwork manufacturing apparatus according to claim 1, comprising: a step of excavating the bottom of the tunnel and performing flooring; a step of installing the invert formwork manufacturing apparatus; a step of discharging the solidifying material using the invert formwork manufacturing apparatus to form a transverse formwork and a longitudinal formwork; a step of placing concrete into the space surrounded by the transverse formwork and the longitudinal formwork. The invert construction method is characterized by the above.

5. An invert construction method using the invert formwork manufacturing apparatus according to claim 2, comprising: a step of excavating the bottom of the tunnel and performing flooring; a step of installing the invert formwork manufacturing apparatus; a step of scanning the tunnel floor surface using the 3D scanner; a step of calculating the difference between the shape of the tunnel floor surface and the designed cross-section; a step of discharging the solidifying material according to the difference using the invert formwork manufacturing apparatus to form a transverse formwork and a longitudinal formwork; a step of placing concrete into the space surrounded by the transverse formwork and the longitudinal formwork. The invert construction method is characterized by the above. ​

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