System and device for water and frost protection for anchoring a lining to a rock or tunnel wall or ceiling

Abstract

This document describes a system for water and frost protection of a rock wall, or tunnel wall or ceiling intended to be fixed to a lining (500) suspended to the rock wall or tunnel wall or ceiling by a plurality anchoring bolts (600) fixed in the rock wall or tunnel wall or ceiling. The system (100) comprises: a sealing disc (300), for sealing an opening or aperture of the lining (500) suspended at a rock or anchoring bolt (600) and along the rock or anchoring bolt (600), the sealing disc (300) being threaded onto the anchoring bolt (600) on the inside of the installed lining (500), the inside being formed by a space or room between the rock wall or tunnel wall or ceiling and the lining (500); and a front disc (200) ensuring a sealing connection between the sealing disc (300) and the lining (500), the front disc (200) threaded onto the anchoring bolt (600) on the outside of the installed lining (500), the outside being formed by a tunnel opening / room.

Description

[0001] TITLE: SYSTEM AND DEVICE FOR WATER AND FROST PROTECTION FOR ANCHORING A LINING TO A ROCK OR TUNNEL WALL OR CEILING

[0002] Field of the invention

[0003] The present invention relates to a front disc for a system for water and frost protection of a rock wall or tunnel wall or ceiling adapted to be fixed to a lining, the system utilizing the front disc, a method for installing the system, and the use of the front disc, system, and method.

[0004] Background of the invention

[0005] In tunnelling, it is required to cover the rock wall or ceiling for different reasons. First it is required for preventing the intrusion of water into the tunnel from surrounding rock formations, secondly it is required to prevent mentioned water from freezing. It is known to use a lining, e.g., in form of a membrane or PE-foam boards, to cover the rock wall or ceiling of tunnels. To prevent the lining from contributing to a rapid expansion of fire in case of a fire accident, it is covered with concrete to form a vault.

[0006] Water is known to leak out of the rock wall or ceiling, and during the winter, this water also tends to freeze, causing ice masses / icicles, frozen road surfaces, fog and bits of e.g., concrete or ice to fall down, etc. Membranes and PE-foam boards are made of combustible materials, potentially causing a fire to rapidly develop throughout the tunnel in case of fire accident inside the tunnel.

[0007] To prevent hazards from water intrusion and fire, it is known to install a watertight and possibly insulating lining or protection on the tunnel walls and ceilings. The lining is suspended from the rock wall or ceiling of the tunnel by means of anchors, typically through a plurality of anchoring bolts anchored in the rock wall or ceiling, whereto the lining is suspended through holes oropenings in the lining being threaded onto the bolts. Different arrangements are used to keep the lining suspended to the bolts. The lining is continuous lining along the tunnel in lengthwise and crosswise sections, forming a watertight, continuous barrier. The lining is thereafter covered with a layer of shotcrete or by installing concrete elements, covering the lining, anchoring bolts and arrangements used to keep the lining suspended, etc.

[0008] At pointwise points where lining is threaded onto the anchoring bolts, leakages may occur due to perforations or openings made in the lining for the rock bolts to penetrate. Using plates or discs together with intermediate seals threaded on to the anchoring bolt, where plates or discs are being positioned at each side of the lining at the rear / back and / or front of the lining for sealing and load bearing purposes are known. Plates or discs together with elastic seals facing the lining on both sides of the lining is one example of such use, where the elastic seals on opposite sides of the lining are establishing a sealing connection by pressing the discs towards the lining, and thus towards each other.

[0009] Before threading the lining onto the anchor bolts, which may be threaded bolts, discs used for sealing purposes are threaded onto the bolts and acts as a sealing and an inner barrier and back support of the lining, at the rear side of the lining. The disc stops at a predefined distance from the tunnel / rock wall or ceiling by means of a stopping device that may be a nut. A seal for sealing the bolt is either preinstalled onto the disc or retrofitted outside of the disc, facing outwards towards the lining. A seal, covering the disc surface facing the lining, is thereafter installed. Then the lining is installed, and the seal preinstalled or retrofitted the disc is sealing both against the bolt and the surface of the lining. A further disc is threaded onto the anchor bolt on the front side of the lining, with or without an additional seal to e.g., seal towards the bolt. A further nut is threaded onto the anchoring bolt and is tightened to keep the lining in place and in locked position, but also to press the two discs on both side of the lining towardseach other and compress the elastic seals so that they prevent water from entering along the bolt or in between the lining and the discs.

[0010] Health, environment and Safety, HES, is a constant consideration throughout the industry. There is a constant increasing requirement to reduce the environmental footprints in all kinds of projects, also projects in the building and construction industry. This sector stands for considerable amount of CO2 emission, waste and use of natural resources. Ergonomic is an important factor for the installation operators.

[0011] The health and safety part are, and should be, given a constant evaluation in the industry. When working up under tunnel ceiling, enhanced handle of objects, reduced weight, and installation procedures are important. To keep the weight as low as possible, use of steel as such plates is not a contribution to such enhanced working environment and health, safety and environment. Another challenge is to keep the objects in place while installing further objects. Further, preventing objects from falling off / down and potentially cause injury to the operators and / or cause additional work are of essence.

[0012] The environmental part of the HES is obtaining more and more attention. The equipment and vehicles, the use of concrete, etc. are a considerable source to carbon emission. To reduce carbon emission, local materials, equipment running on renewable energy / biofuels, recycle materials from other projects, etc. are used. The industry is constantly looking for improved or new solutions to reduce the carbon emission and reduce energy consumption in general.

[0013] Anchoring bolts and structural components used to control the structural ability of the concrete are traditionally made from steel. Alternative materials to steel exist, e.g., fiber reinforced composites and other composite materials. These alternative materials are sensitive to heat. In case of a fire, the thickness of concrete applied governs the ability of the vault to keep itsstructural integrity. A thicker concrete layer is more protective towards the heat. Since concrete is a substantial contributor to CO2 emissions, the heat sensitivity of the vault structure is a problem. The concrete also serves as protection of the reinforcement net towards rust. The reinforcement net is suspended from the lining and is a load bearing element for the layer of concrete. Using alternative materials instead of steel, is one contributor to the reduction of CO2 emission. However, the heat sensitiveness that such materials present, and how the fire protection of these is solved today, prevents from utilizing such emission-reducing materials.

[0014] There is thus a need for solutions to overcome the above-mentioned problems.

[0015] Objects of the present invention

[0016] An object of the present invention is to reduce the environmental impact in tunnelling.

[0017] A further object of the present invention is to increase the lifetime of tunnel structures.

[0018] Yet another object of the present invention is to prevent water intrusion from the rock wall or ceiling of the tunnel to the tunnel cavity.

[0019] Another object of the present invention is to prevent formation of ice on the inside of the protecting membrane and / or the fire protection in a tunnel.

[0020] A further object of the present invention is to prevent ice from falling down onto or build up in the roadway in the tunnel.

[0021] Yet another object of the present invention is to reduce the weight of the components used in in water, frost, and fire protection of tunnels.

[0022] A further object of the present invention is to improve health, environment and safety for the operators installing the tunnel.Another object of the present invention is to ease the number of unique components in the tunnel construction.

[0023] Yet another object of the present invention is to reduce the energy consumption in the transport and handling of the components used in in water, frost, and fire protection of tunnels.

[0024] A yet further object of the present invention is to eliminate or at least reduce the need of corrosion protection in tunnels.

[0025] Another objective of the present innovation is to reduce CO2 footprint in the construction of tunnels.

[0026] Summary of the invention

[0027] In the following, and throughout the specification, the following terms means:

[0028] The term “circular” means circular, semicircular, oval, etc.

[0029] The term “lining” means and includes membrane or PE-foam.

[0030] In a first aspect, the present invention relates to a front disc for a system for water and frost protection of a rock wall or tunnel wall or ceiling adapted to be fixed to a lining, the lining being adapted to be fixed to the rock wall tunnel wall or ceiling by a plurality anchoring bolts fixed in the rock wall or tunnel wall or ceiling, the front disc comprises means for anchoring concrete.

[0031] Providing means for anchoring concrete in the front disc provides the distribution of the load of the concrete not only to the reinforcement net, but the front disc also serves as a load bearing component for the concrete.

[0032] In embodiments, the means for anchoring concrete is a plurality of openings in the disc, wherein the plurality of openings extends along a central axis of the disc, extending from a front side of the disc adapted to face away fromthe lining when installed, towards a back side of the disc adapted to face the lining when installed.

[0033] In embodiments, a cross-sectional area of each opening, the cross-sectional area defined by a plane perpendicular to the central axis of the disc, is increasing from the front side of the disc towards the back side of the disc.

[0034] In embodiments, the front disc comprises a central through hole, wherein the central through hole is arranged centrally on the front disc and adapted to be threaded onto an anchoring bolt.

[0035] In embodiments, the front disc comprises:

[0036] a central circular portion adapted to provide a press towards a side of the lining facing the tunnel room / opening and to press towards sealings of an opposite sealing disc on the other side of the lining, turning inwards towards the rock wall or tunnel wall or ceiling;

[0037] - a circumferential outer ring concentrically arranged around the central circular portion in the periphery of the front disc and adapted to provide a press towards the side of the lining facing the tunnel room / opening and to press towards sealing of the opposite sealing disc.

[0038] In embodiments, the front disc comprises a plurality of ribs between the central circular portion and the circumferential outer ring, and between the ribs. The ribs stiffen the front disc to withstand large bending forces.

[0039] In embodiments, the plurality of ribs extends radially between the central circular portion and the circumferential outer ring. Radially arranged ribs provides better force distribution on the disc.

[0040] In embodiments, at least one center rings concentrically arranged around the central circular portion of the front disc, between the central circular portion and the circumferential outer ring. The center ring providing a stiffer front disc, withstanding even larger bending forces.The sealing support surface constitutes the surface of the center ring, the surface of the circumferential outer ring and / or the surface of the ribs, and / or the surface of the central circular portion on the back side of the front disc.

[0041] In embodiments, the plurality of openings is formed between the plurality of ribs, the central circular portion and the circumferential outer ring.

[0042] In embodiments, the plurality of openings is formed between the plurality of ribs, the central circular portion the center ring and between the plurality of radial ribs, the center ring and the circumferential outer ring

[0043] In embodiments, the circular portion of the front disc comprises a concentrically arranged, the circular recess is extending from the front side towards the back side of the front disc and is adapted to receive a tightening nut. The tightening nut being immersed or partially immersed in the recess. At least 1 / 2 or 2 / 3 of the height of the nut in the axial direction is surrounded by the disc. Providing a lower building height of the disc with the nut than if the disc has no or only a shallow recess where the nut is arranged outside the disc for a high building height. Hence, the thickness of the shotcrete layer is reduced. Less shotcrete is needed, which in turn has many beneficial advantages, e.g. environmental advantages. E.g. reducing emission, and especially CO2 emission which is a substantial challenge and problem in the industry.

[0044] In embodiments, the circular recess comprises a supporting surface in a bottom of the circular recess. The supporting surface adapted to receive the tightening nut.

[0045] In embodiments, the circular recess comprises a rounded inner corner between the support surface and a recess side wall of the circular recess. The rounded inner corner is adapted to receive a rounded outer edge of atop portion of the nut. A slanting side wall adapted to receive an equivalent surface tangentially continuing from the rounded bottom surface of the nut.

[0046] The rounded corner provides sufficient stiffness and reduces stress in the corner and thus the risk of fraction.

[0047] In embodiments, the openings are thorough openings extending through the front disc.

[0048] In embodiments, the means for anchoring concrete is a plurality of openings formed between the plurality of ribs, the central circular portion and / or the circumferential outer ring.

[0049] In embodiments, the openings extend from the front side of the front disc to a bottom surface of the openings, wherein the bottom surface extends to the back side of the front disc, the back side of the front disc adapted to face the lining when the front disc is installed.

[0050] In embodiments, each opening extends from the front side of the front disc to a bottom surface of the opening, wherein the bottom surface extends to the back side of the front disc, the back side of the front disc adapted to face the lining when the front disc is installed.

[0051] In embodiments, each opening comprises walls, extending from the front side to the back side of the front disc.

[0052] In embodiments, at least one of the walls is inclined with a negative draft angle in a direction pointing along the central axis from the front side of the front disc towards a back side of the front disc.

[0053] In embodiments the means for anchoring concrete is beads or bulbs projecting out from at least one of the walls of the openings of the front disc.In embodiments, the means for anchoring concrete is a ridge or ridges arranged on at least one of the walls of the opening of the front disc. The ridge or ridges extending in a direction perpendicular to a central axis of the front disc.

[0054] In embodiments, the means for anchoring is formed by barbs downwards one or more of the walls of each opening towards the back side of the front disc, the cross section looking like the silhouette of a spruce tree.

[0055] In embodiments, the means for anchoring is formed by the plurality ribs, wherein each rib is having a cross section being T-formed or formed as a cross. The top of the T is forming a top of the rib on the front side of the disc

[0056] In embodiment, the recess side wall of the circular recess is inclined with a positive draft angle in a direction pointing along the central axis from the front side of the front disc towards the back side of the front disc adapted to receive an equivalently portion of a nut.

[0057] In a second aspect, the present invention relates to a system for water and frost protection of a rock wall or tunnel wall or ceiling intended to be fixed to a lining, the lining being intended to be fixed to the rock wall or tunnel wall or ceiling by a plurality anchoring bolts fixed in the rock wall or tunnel wall or ceiling, the system comprises:

[0058] - two nuts, each nut comprising a top portion having a top surface and a rounded edge between an outer inclined wall surface of the top portion and the top surface, the nut further comprising a tool receiving portion;

[0059] - a sealing disc, the sealing disc comprises a front surface adapted to abut against one of the two nuts, a surface seal on a sealing surface, the sealing surface located at the opposite side of the front surface, and a central through hole, the surface seal comprises an outer peripheral seal, an inner seal encircling the central through hole, acentral seal between the outer peripheral seal and the inner seal, and an inner lip between the inner seal and the central through hole; and a front disc.

[0060] In a third aspect, the present invention relates to a method for installing a system for water and frost protection of a rock wall or tunnel wall or ceiling to a rock or anchoring bolt, the method comprises the steps of:

[0061] 1) screwing a nut onto a pre-installed anchoring or rock bolt in a rock wall or tunnel wall or ceiling;

[0062] 2) threading a sealing disc onto the anchoring or rock bolt until the sealing disc abuts against the nut, the sealing surface of the sealing disc facing outwards, the opposite way of the side of the sealing disc abutting against the nut;

[0063] 3) threading a membrane or lining onto the anchoring or rock bolt 600 until it abuts against the sealing disc;

[0064] 4) threading a front disc onto the pre-installed anchoring or rock bolt until the back side of the front disc abuts against the membrane or lining; 5) screwing a further nut onto the anchoring or rock bolt, with the top portion of the nut towards the front disc, until the further nut abuts against the support surface of the circular recess of the front disc; 6) tightening the further nut ensuring a sealing connection between the installed components.

[0065] In a fourth aspect, the present invention relates to a use of the front disc in a system for water and frost protection of a rock wall or tunnel wall or ceiling.

[0066] In a fifth aspect, the present invention relates to a use of the system for water and frost protection of a rock wall or tunnel wall or ceiling in a tunnel.

[0067] In a sixth aspect, the present invention relates to a use of the method for installing a system for water and frost protection of a rock wall or tunnel wall or ceiling to a rock or anchoring bolt.In a seventh aspect, the present invention relates to a use of the system for water and frost protection of a rock wall or tunnel wall or ceiling for installing fire protection in a tunnel.

[0068] The front disc is formed to provide an anchoring effect to the shotcrete for holding the vault in a fire and to enclose at least part of an outer tightening nut holding the front disc towards a lining and a back disc, the nut enclosed within a centrally arranged recess of the front disc. The front disc enables to move the nut higher up towards the lining, being a membrane or PE-foam in the vault construction, thus the layer thickness of the shotcrete is defined from a point closer to the lining. In opposite to standard design wherein a disc is without such recess, and the nut builds height together with the height of the disc, and thus the layer thickness of the shotcrete being defined from a point further away from the lining. Thus, the thickness of the shotcrete from the lining is reduced with the new front disc receiving the nut in a central circular recess of the disc. In an event of fire, it is important to provide a certain thickness of the concrete to ensure that the concrete protects the front disc and other critical components such the nut and anchoring bolt when the temperature in the tunnel increases to a critical temperature, at least for a specific period of time, and preferably until the tunnel is evacuated. The thickness of the concrete significantly extends the time before the vault collapses into the traffic zone of the tunnel room.

[0069] The front disk is utilizing the volume between the lining and of the mesh reinforcement for anchoring between the bolt and the fire protection (shotcrete or concrete element), by forming the front disc to provide a grip for the concrete within the disc. And further providing a lower built height of the front disc by providing a recess in the front disc for receiving a nut to be tightened towards the front disk, pressing the front disc towards an outward facing side of the lining and the back disk installed on the opposite inwards facing side of the lining, that being inwards towards the rock wall, and / or tunnel wall or ceiling. After the system is being installed, further equipment for reinforcement of concrete is installed, e.g., mesh reinforcement, beforeapplying shotcrete outside the installed equipment of the tunnel. The shotcrete is applied to cover the installed equipment of the tunnel. The higher the front disc and nut builds, the thicker the shotcrete, in order to protect fixing and structural components e.g., nut and anchoring bolt made from materials that are more sensitive to heat than traditional materials. The production of concrete is a substantial source to the CO2 emission in the industry. Reducing the consumption of concrete will potentially be a large contributor to the reduction of the environmental footprint in the industry. The front disc of the invention, providing a lower building height and an anchor for the concrete, requires less concrete to cover the front disc together with other installed equipment on the outside of the lining to obtain sufficient heat protection from a fire. The thickness of the layer of the shotcrete can thus be reduced. A thinner layer of shotcrete also provides less resources, as less concrete is used, less heavy work for the operators installing the equipment in the tunnel, less transport of concrete, etc.

[0070] The system for water and frost protection for tunnel walls and rock walls is a complex system safeguarding a plurality of considerations regarding preventing water intrusions through the system, formation of ice, anchoring of lining, fire protection, anchoring of reinforcement, anchoring of concrete, etc.

[0071] The system for water and frost protection of a tunnel or rock wall or ceiling adapted to be fixed to a lining to be fixed to the tunnel or rock wall or ceiling by a plurality anchoring bolts fixed in the tunnel or rock wall. The lining is threaded onto the anchoring bolts through apertures or openings in the lining. Water leaking out of the rock wall or ceiling of the tunnel tends to travel along the anchoring bolts and through the apertures or opening of the lining and fall into the open room of the tunnel. To prevent water leakages or ice formations during winter season, the apertures or openings in the lining are sealed off. The mentioned system is provided to ensure a watertight solution both along the anchoring bolt and in the aperture or opening of the lining. The invention is utilizing sealing discs on the inside of the liningcomprising sealings towards the surface of the lining and towards the anchoring bolt and a front disc on the outside of the lining providing pressure by means of a nut pressing the front disc towards the sealing and the sealing disc to ensure a sealing connection with the lining.

[0072] The invention is utilizing the front disc as an anchor for the layer of concrete being applied as shotcrete. Projections, barbs, edges, bulbs, slanted walls etc. is being utilized as grips for the concrete, increasing the friction between the front disc material and the concrete.

[0073] The front disc is made of a stiff material, typically a plastic material, but it is also possible to produce it in a metal material, such as aluminium. The plastic material being a material than can be thermoformed compression moulded or injection moulded and is for example of materials such as polypropylene, PP, high density polyethylene, HDPE, polyvinyl chloride, PVC, polyamide / nylon PA or acrylonitrile butadiene styrene, ABS. The material can be filled with glass fibers or other fiber-reinforcements e.g., basalt.

[0074] The back disk can be made of equal materials, but can also utilize recycled plastic materials, such as recycled plastic from the sea and recycled ropes typically being ropes from sea farming, towing of boats, and other areas of application at sea. The sealing material in the back disc can be synthetic rubber such as, but not limited to

[0075] thermoplastic elastomer, TPE, styrene ethylene butylene styrene, SEBS, or thermoplastic olefin, TPO.

[0076] At least the front disc should be resistant to chemicals.

[0077] Description of the figures

[0078] Embodiments of the present invention will now be described, by way of example only, with reference to the following figures, wherein:Figure 1 shows schematically and in perspective a prior art sealing disc as an ingoing part in a system for water and frost protection.

[0079] Figure 2 shows schematically and in perspective an embodiment of a front disc of a system for water and frost protection of a tunnel or rock wall or ceiling.

[0080] Figure 3 shows schematically and in perspective the front disc from the opposite side of the front disc than in figure 2.

[0081] Figure 4a an 4b shows schematically a cross section of a system for water and frost protection of a tunnel or rock wall or ceiling threaded onto the anchoring bolt, on both sides of the lining before and when tightened to provide a sealing connection towards a lining.

[0082] Figure 5a, being equal to figure 4a, encircles a detail enlarged in figure 5b.

[0083] Figure 6 shows schematically a cross section of the front disc with bottom surfaces of the openings showing inclined surfaces of the walls of the openings as means for anchoring concrete.

[0084] Figure 7 shows schematically a cross section of the front disc with thorough openings showing different embodiments as means for anchoring concrete.

[0085] Description of preferred embodiments of the invention

[0086] The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to a system for water and frost protection of a tunnel or rock wall or ceiling adapted to be fixed to a lining, a front disc comprisedin the system, a method for installing the system, and the use of the front disc, the system and the method.

[0087] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0088] Figure 1 shows schematically and in perspective a prior art sealing disc 200, 300 as an ingoing part in a system for water and frost protection 100. The sealing disc 300 serving as both a sealing disc 300 and a front disc 200 to seal towards the lining 500 on both sides of the lining 500. The disc 300 having integrated sealings (not shown), a sealing 330 (not shown) centrally arranged to seal towards an anchoring bolt 600 located in the tunnel or rock wall or ceiling and the sealing further extending to the peripheral part of the disc where it forms a peripheral sealing 332 along the rim of the disc 300, being the sealing arranged to seal towards the lining 500. The system for water and frost protection 100 is first arranged with a nut 400 threaded onto the anchoring bolt 600, to serve as a stopping means to keep the lining 500 a certain distance from the tunnel or rock wall or ceiling. Thereafter, threading the inner arranged disc 300 onto the bolt 600, the side of the disc 300 without a sealing, as can be seen in figure 1 to face the nut 400, the other side with the sealing towards the lining 500 that is thereafter threaded with an opening in the lining 500 onto the anchoring bolt 600 followed by a new disc 300 with its sealing side 331 towards the disc 300 and an outer nut 400 to be threaded onto and tightening towards the last disc 300 so that the discs 300 are pressing from both side of the lining 500 towards the lining 500 and thus sealing around the opening in the lining 500 and along the anchoring bolt. 600 The open cavities seen on the front side 320 of the disc300, the side facing away from the lining 500, are having walls with straight walls or walls with draft angles, so that the disc 300 can be removed from a moulding tool forming the plastic disc 300. These walls are not able to serve as anchoring for concrete for fire protection outside of the lining, due to the straight walls or the direction of the draft angle. The outer nut 400 together with the outer disc 300 building a height with which shotcreting for fire protection outside the lining 500, necessary equipment for reinforcement and the anchoring bolt 60 to cover, providing a layer of concrete for the fire protection.

[0089] Figure 2 shows schematically and in perspective an embodiment of a front disc 200. The front disc 200 is shown with its front side 201 of the front disc 200, the front side 201 is adapted to face away from the lining 500 when installed. The front disc 200 has a back side 202 on the opposite side of the front side 201 of the front disc 200, the back side 202 is adapted to face the lining 500 when installed. The front disc 200 being circular or semicircular. The front disc 200 comprising a central circular or semicircular portion 210. The front disc 200 further comprising a central circular through hole 211 for threading the front disc 200 onto an anchoring bolt 600. A circular recess 212 is concentrically arranged with respect to the central through hole 211 and the central circular or semicircular portion 210. The recess 212 comprises a support surface 213 and a rounded inner corner 214 between the support surface 213 and a recess side wall 215. The nut 400 comprises a top portion 410 and a tool receiving portion 420. The top portion 410 has a top surface 411 adapted to abut the support surface 213 of the front disc 200 when installed. A rounded outer edge 412 between an outer wall 413 of the top portion 410 of the nut 400 and the top surface 411 of the nut 400. The rounded outer edge 412 is abutting / received by the rounded inner corner 214 of the recess 212. The nut 400 further comprising a tool receiving portion 420 to receive a tool for screwing the nut 400 onto mentioned anchoring bolt 600 and to screw the nut 400 to press the front disc 200 towards the lining 500 and towards a sealing disc 300 (not shown) to seal towards the lining 600 and to activate a surface seal 330 (not shown) of thesealing disc 300 installed on the opposite side of the sealing. The tool receiving portion 420 preferably being formed as a hexagon to receive an adjustable wrench. The recess 212 is adapted to receive the nut 400 with its rounded inner corner 214 and support surface 213 facing the rounded edge 412 and the top surface 411 of the nut 400. The front disc 300 is further having a circumferential ring 220 at the outer rim of the disc 200, and ribs 240 extending between the central circular or semicircular portion 210 and the circumferential ring 220. In figure 2, the ribs 240 are seen extending radially out from the central circular or semicircular portion 210towards the circumferential ring 220. The ribs 240 are not limited to extending radially out, they may form any combinations between the outer rim of the disc 200 and the circumferential ring 210, e.g., a grid system of squares, triangles, combinations of squares and triangles, etc. A center ring 230 is arranged between the circumferential ring 220 and the ring-shaped sidewall 213 of the recess 212. The center ring 230 is preferably concentrically arranged with respect to the central circular or semicircular portion 210 and the circumferential ring 220. The back side 202 of the front disc 200 forms a sealing support surface 260 adapted to abut the sealing when installed. The sealing support surface 260 being arranged to press towards sealing of a sealing disc 300 (not shown), facing the front disc 200 and installed on the opposite side of the lining 500.

[0090] A plurality of openings 250 through the front disc 200 are formed between the central circular or semicircular portion 210, the center ring 230 and the ribs 240, and between the circumferential ring 220, the center ring 230 and the ribs 240. Optionally between the central circular or semicircular portion 210, the circumferential ring 220 and the ribs 240 on discs 200 without a center ring 230 (not shown). At least one side wall 251 of each opening 250 is having a draft angle or tapered face with respect to a plane perpendicular to a central axis of the front disc 200, wherein the draft angle or tapered face is having a negative draft angle from said plane, in a direction pointing along the central axis from the front side 201 of the front disc 200 towards a back side 202 of the front disc 200, the back side 202 being opposite the frontside 201. The openings 250 are thus enabling the front disc 200 to be ejected from a moulding tool forming the front disc 200 and are adapted to provide anchoring for shotcrete being applied to cover the lining 500 together with the front disc 200, anchoring bolt 600 projecting out from the lining 500, the nut 400, reinforcement and holders for reinforcement, at the side of the lining 500 facing the tunnel opening / room, the layer of shotcrete provides fire protection to the equipment covered by the concrete, and the space or room between the tunnel wall or ceiling and the lining 500. The negative draft angle or tapered face provides anchoring of the shotcrete. To provide an anchoring for the shotcrete being a means for anchoring, a cross-sectional area of each opening 250, the cross-sectional area being defined by a plane perpendicular to a central axis 203 (not shown) of the disc 200, is increasing from the front side 201 of the disc 200 towards the back side (202) of the disc (200).

[0091] Figure 3 shows schematically and in perspective the front disc 200 showing its back side 202, being the opposite side of the front side 201 of the front disc 200 shown in figure 2. The back side 202 facing the lining 500 when the front disc 200 is installed. The back side 202 facing the lining 500 preferably forming a convex surface. The circumferential ring 220, the center ring 230 and the central through hole 211 can be seen. Additionally, a circular lip 270 is formed projecting out from a sealing support surface 260 opposite the support surface 213 of the recess 212 concentrically to and along the central through hole 211 of the front disc 200. A chamfer 280 is formed between the central through hole 211 of the front disc 200 and the circular lip 270, the chamfer 280 being adapted to receive a sealing inner lip 334 from the sealing disc 300 to squeeze and press the sealing disc 300 towards the threads of the anchoring bolt 600 for a sealing connection provided to reduce or eliminate water leakage along the anchoring bolt 600, see figure 5b.

[0092] Figure 4a an 4b shows schematically a cross section of a system 100 for water and frost protection of a rock wall or tunnel wall or ceiling threadedonto the anchoring bolt 600, on both sides of the lining 500. The system 100 comprises two stopping means being e.g., two nuts 400 adapted to be threaded onto the anchoring bolt 600, first one nut 400 is threaded onto the anchoring bolt 600 at a predefined distance from the rock wall or tunnel wall or ceiling.

[0093] The system 100 further comprises a sealing disc 300 adapted to be threaded onto the anchoring bolt 600 until it abuts against the nut 400 first installed. The sealing disc 300 comprising a central through hole 310 adapted to be threaded onto the anchoring bolt 600, the sealing disc 300 having a front surface 320, being the surface abutting against the nut 400 and facing the rock wall or tunnel wall or ceiling.

[0094] The sealing disc 300 is further comprising a sealing surface 331, opposite the front surface 320, adapted to face the lining 500 and seal the opening or aperture of the lining 500 threaded onto the anchoring bolt 600 subsequent to the sealing disc 300. The sealing surface 331 comprises seals 330 protruding out of the sealing surface 331 and are adapted to face towards the lining 500, preferably seals 330 forming an integrated unit with the sealing disc 300, and the seals 330 preferably forming a monolithic unit. The seals 330 comprise an outer peripheral seal 332, the outer peripheral seal 332 located along the rim of the sealing disk 300, an inner seal 333 encircling the central through hole 310 of the sealing disc 300, and a central seal 335 located between the outer 332 and inner seal 333. The inner seal 333 comprising an inner lip 334 providing the sealing towards the anchoring bolt 600 and towards the chamfer 280 providing a sealed connection. The inner seal 333 is also adapted to seal towards the anchoring bolt 600. The positions of the peripheral seal 332, the central seal 335 and the inner seal 333 corresponds to the positions of the circumferential ring 220, center ring 230 and the recess sidewall 215 and support surface 213 of the recess 210 of the front disc 220, respectively, and when tightened towards each other provides sealing towards the lining 500 and the anchoring bolt 600.The front surface 320 of the sealing disc 300 comprising a front seal 321 protruding out from the front surface 320 and encircling the through hole 310 of the sealing disc 300. The front seal 321 is adapted to provide a sealing between mentioned nut 400 and the front disc 300 towards the anchoring bolt 600. The front seal 321 is adapted to deform as it is being squeezed into a central recess 421 of the nut 400 encircling a central through hole 422 of mentioned nut 400 when the sealing disc 300 is pressed towards mentioned nut 400. The front seal 321 being squeezed into the central recess 421 of the nut 400 and simultaneously pressed towards the threads of the anchoring bolt 600, providing a sealed connection between the nut 400, sealing disc 300, and the threads of the anchoring bolt 600. The front surface 320 of the sealing disc 300, as opposed to the convex back side 202 of the front disc 200, is being concave The discs 200, 300 being convex and concave respectively, it is possible for the nut 400 screwed into central through hole 211 of the central circular portion 210 in the front disc 200 to be screwed as close as possible towards the lining 500, without deforming and creating folds in the lining. The heat sensitive components, the front disc 200 together with the nut 400, are moved further into the construction, which is important as the front disc 200 is having a load-bearing function for the concrete. The disc 200, 300 is not limited to being convex and concave respectively, they may also be flat.

[0095] After installation of the lining 500, the system 100 comprising the front disc 200 is pressed towards the lining 500 and towards the sealings 330 on the sealing surface 331 of the sealing disc 300, the front disc 200 being threaded onto to the anchoring bolt 600, the back side 202 of the front disc 200 facing the lining 500. Thereafter a further nut 400 is threaded onto the anchoring bolt 600, the nut 400 being screwed towards the front disc 200 until it abuts against the support surface 213 of the recess 212 of the front disc 200, and thus, at least partly, encompassed by the recess 212 of the front disc 200, providing a lower building height of the system 100 outside the lining 500 than if the nut 400 was abutting against the front disc 200 without the recess 212 of the front disc 200.In figure 4a, the system is shown before tightening the nut 400 provided at a front side of the lining 500, being the side facing the tunnel opening / room. In figure 4b, the system is shown after the nut 400 provided at the front side of the lining 500 is tightened, until a sealing connection is established, ensuring a sealed connection between the system 100 and the opening or aperture of the lining 500 and along the anchoring bolt 600.

[0096] Figure 5a, being equal to figure 4a, encircles a detail enlarged in figure 5b, where a volume A of the circular inner lip 334 of the sealing disc 300 is marked and a receiving area, between the threads of the anchoring bolt 600 and the chamfer 280 formed from the central through hole 211 of the front disc 200 to the circular lip 270, is marked volume B. The marked receiving volume V is adapted to receive the volume A of the sealing circular inner lip 334 of the sealing disc 300. When the discs 200, 300 are pressed together on both sides of the lining 500, the mentioned volume A is deformed as it is being squeezed and pressed towards the threads of the anchoring bolt 600 into the marked receiving volume V, see figure 4b, for a sealing connection provided to reduce or eliminate water leakage along the anchoring bolt 600. The volumes A and V are approximately equal, the volume arranged in the front disc 200 is smaller, so that the volume of the sealing material of the back disc 300 is forced to change shape and therefore grow or squeeze in towards the bolt 600 and adapt to the shape of the bolt 600, providing a watertight connection.

[0097] Figure 6 shows schematically a cross section of the front disc 200 with bottom surfaces 256 in the openings 250. An embodiment of means for anchoring is shown as walls of the openings 250 being slanted with a negative draft angle in relation to the support surface 213 in a direction pointing along the central axis 203 from the front side 201 of the front disc 200 towards the back side 202 of the front disc 200. The circular recess 212 of the central circular portion 200 having an inclined recess side wall 215 which together with the support surface 213 and the rounded inner corner214 provide a large contact surface with the nut 400 being tightened into a top surface 411, an outer rounded edge 412 and the wall surface 413 of the top portion 410 of the nut 400, wherein the wall surface 413 is forming an inclined surface, when the system 100 is installed.

[0098] Figure 7 shows schematically a cross section of the front disc 200 with thorough openings 250 through the disc 200 showing different embodiments of means for anchoring concrete. Means for anchoring is shown as walls 251 of the openings 250 being slanted 252, as described in figure 6, having bulbs 253, having a T-formed cross section 254, and / or having barbs 255. Means for anchoring could also be an edge or a plurality of projections along the periphery of the front disc 200.Table 1

[0099]

Claims

Claims1. A front disc (200) for a system for water and frost protection of a rock wall or tunnel wall or ceiling adapted to be fixed to a lining (500), the lining (500) being adapted to be fixed to the rock wall tunnel wall or ceiling by a plurality anchoring bolts (600) fixed in the rock wall or tunnel wall or ceiling, the front disc (200) comprises means for anchoring concrete.

2. The front disc (200) according to claim 1 , wherein the means for anchoring concrete is a plurality of openings (250) in the disc (200), wherein the plurality of openings (250) extends along a central axis (203) of the disc (200), extending from a front side (201 ) of the disc (200) adapted to face away from the lining (500) when installed, towards a back side (202) of the disc (200) adapted to face the lining (500) when installed.

3. The front disc (200) according to claim 2, wherein a cross-sectional area of each opening (250), the cross-sectional area defined by a plane perpendicular to the central axis (203) of the disc (200), is increasing from the front side (201 ) of the disc (200) towards the back side (202) of the disc (200).

4. The front disc (200) according to any preceding claim, wherein the front disc (200) comprises a central through hole (211), wherein the central through hole (211) is arranged centrally of the front disc (200) and adapted to be threaded onto an anchoring bolt (600).

5. The frond disc (200) according to any one of the claims 2 to 4, wherein the front disc comprises- a central circular ring portion (210) adapted to provide a press towards a side of the lining (500) facing the tunnel room / opening and to press towards sealings (330) of an opposite sealing disc (300) onthe other side of the lining (500), turning inwards towards the rock wall or tunnel wall or ceiling;- a circumferential outer ring (220) concentrically arranged around the central circular portion (210) in the periphery of the front disc (200) and adapted to provide a press towards the side of the lining (500) facing the tunnel room / opening and to press towards sealing (332) of the opposite sealing disc (300).

6. The front disc (200) according to claim 5, wherein the front disc (200) comprises a plurality of ribs (240) between the central circular portion (210) and the circumferential outer ring (220), and between the ribs (240).

7. The front disc (200) according to claim 6, wherein the plurality of ribs (240) extends radially between the central circular portion (210) and the circumferential outer ring (220).

8. The front disc (200) according to claims 6 or 7, wherein at least one center ring (230) is concentrically arranged around the central circular portion (210) of the front disc (200), between the central circular portion (210) and the circumferential outer ring (220).

9. The front disc (200) according to claim 6 or 7, wherein the plurality of openings (250) is formed between the plurality of ribs (240), the central circular portion (210) and the circumferential outer ring (220).

10. The front disc (200) according to claim 8, wherein the plurality of openings (250) is formed between the plurality of ribs (240), the central circular portion (210) the center ring (230) and between the plurality of radial ribs (240), the center ring (230) and the circumferential outer ring (220).

11. The front disc (200) according to any one of claims 5-10, wherein the circular portion (210) of the front disc (200) comprises a concentrically arranged recess (212), the circular recess (212) is extending from the frontside (201 ) towards the back side (202) of the front disc (200) and is adapted to receive a tightening nut (400),.

12. The front disc (200) according to claim 11 , wherein the circular recess (212) comprises a supporting surface (213) in a bottom of the circular recess (212), the supporting surface (213) adapted to receive a top surface (411) of the tightening nut (400).

13. The front disc (200) according to claim 12, wherein the circular recess (212) comprises a rounded inner corner (214) between the support surface (213) and a recess side wall (215) of the circular recess (212), wherein the rounded inner corner (214) is adapted to receive a rounded outer edge (411) of a top portion (410) of the nut (400).

14. The front disc (200) according to any one of the claims 2 to 13, wherein the openings (250) are thorough openings, extending through the front disc (200).

15. The front disc (200) according to any one of the claims 2 to 13, wherein the openings (250) extend from the front side (201 ) of the front disc (200) to a bottom surface (256) of the openings (250), wherein the bottom surface (256) extends to the back side (202) of the front disc (200), the back side (202) of the front disc (200) adapted to face the lining (500) when the front disc (200) is installed.

16. The front disc (200) according to one of the claims 2-15, wherein each opening (250) comprises walls (251), extending from the front side (201) to the back side (202) of the front disc (200).

17. The front disc (100) according to claim 16, wherein at least one of the walls (251) is inclined with a negative draft angle in a direction pointing along the central axis (213) from the front side (201 ) of the front disc (200) towards the back side (202) of the front disc (200).

18. The front disc (200) according to any one of the claims 2 to 16, wherein the means for anchoring concrete (290) is beads or bulbs projecting out from at least one of the walls (251 ) of at least one of the openings (250) of the front disc (200).

19. The front disc (200) according to claim 16, wherein the means for anchoring concrete (290) is a ridge or ridges arranged on at least one of the walls (251 ) of at least one of the openings (250) of the front disc (200), extending in a direction perpendicular to a central axis of the front disc (200).

20. The front disc (200) according to claim 16, wherein the means for anchoring concrete (290) is formed by barbs downwards at least one of the walls (251 ) of at least one of the openings (250), towards the back side (202) of the front disc (200).

21. The front disc (200) to one of the claims 6-20, wherein the ribs (240) are having a cross section being T-formed, the top of the T is forming a top of the rib (240) on the front side (201 ) of the disc (200).

22. The front disc (200) to one of the claims 13-21 , wherein a recess side wall (215) of the circular recess (212) is inclined with a positive draft angle in a direction pointing along the central axis (213) from the front side (201) of the front disc (200) towards the back side (202) of the front disc (200)adapted to receive an equivalent portion of a nut (400).

23. A system (100) for water and frost protection of a rock wall or tunnel wall or ceiling intended to be fixed to a lining (500), the lining (500) being intended to be fixed to the rock wall or tunnel wall or ceiling by a plurality anchoring bolts fixed in the rock wall or tunnel wall or ceiling, the system (100) comprises:- two nuts (400), each nut (400) comprising a top portion (410) having a top surface (411) and a rounded edge (412) between an outer inclined wall surface (413) of the top portion (410) and the top surface (411), the nut (400) further comprising a tool receiving portion (420);- a sealing disc (300), the sealing disc (300) comprises a front surface (320) adapted to abut against one of the two nut (400), a surface seal (330) on a sealing surface (331), the sealing surface (331) located at the opposite side of the front surface (320), and a central through hole (310), the surface seal (330) comprises an outer peripheral seal (332), an inner seal (333) encircling the central through hole (310), a central seal (335) between the outer peripheral seal (332) and the inner seal (333), and an inner lip (334) between the inner seal (333) and the central through hole (310); and- a front disc according to any preceding claim.

24. A method for installing a system (100) for water and frost protection of a rock wall or tunnel wall or ceiling according to claim 23 to a rock or anchoring bolt (600), the method comprises the steps of:1) screwing a nut (400) onto a pre-installed anchoring or rock bolt (600) in a rock wall or tunnel wall or ceiling (500);2) threading a sealing disc (300) onto the anchoring or rock bolt (600) until the sealing disc (300) abuts against the nut (400), the sealing surface (331) of the sealing disc (300) facing outwards, the opposite way of the side of the sealing disc (300) abutting against the nut (400);3) threading a membrane or lining onto the anchoring or rock bolt (600) until it abuts against the sealing disc (300);4) threading a front disc (200) according to one of the claims 1-7 onto the pre-installed anchoring or rock bolt (600) until the back side (202) of the front disc (200) abuts against the membrane or lining (500); 5) screwing a further nut (400) onto the anchoring or rock bolt (600), with the top portion (410) of the nut (400) towards the front disc (200), untilthe further nut (400) abuts against the support surface (213) of the circular recess (212) of the front disc (200);6) tightening the further nut (400) ensuring a sealing connection between the installed components.

25. A use of the front disc (200) according to one of the claims 1-22 in a system (100) for water and frost protection of a rock wall or tunnel wall or ceiling according to claim 24.

26. A use of the system (100) for water and frost protection of a rock wall or tunnel wall or ceiling according to claim 23 in a tunnel.

27. A use of the method for installing a system (100) for water and frost protection of a rock wall or tunnel wall or ceiling according to claim 23 to a rock or anchoring bolt (600).

28. A use of the system (100) for water and frost protection of a rock wall or tunnel wall or ceiling according to claim 23 for installing fire protection in a tunnel.

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