EP3591166B1 - Tunnel lining composed of at least two concrete elements - Google Patents

Description

The invention relates to a tunnel lining composed of at least two concrete elements, each with at least one protective element connected to the concrete element, the protective element having a protective section which has a first side facing the concrete element, on which at least one connecting element for establishing a holding connection of the protective section with the Concrete element is provided, the protective section consists of at least one plastic, the protective element having at least one protective element seal connected to the protective section, the connection to the protective section being gas-tight and liquid-tight, with a joint between the at least two concrete elements arranged for tunnel lining is present, wherein the joint is sealed gas-tight and liquid-tight to the tunnel interior by at least one protective element seal with a first sealing effect.

Such tunnel construction with concrete elements with protective elements are among other things WO 2005/024183 A1 , WO 2011/085734 A1 , WO 2015/139807 A2 and from WO 2017/008913 A1 known. Alternative embodiments are from JP 2004132002 , DE 3800630 A1 and US 6328501 B1 known.

The concrete elements used here are also referred to in the technical language as "tubbings" and are z. B. as part of tunnel construction mechanical tunneling by means of shield driving used. Such tunnel lining is used, for example, in connection with tunnel boring machines which comprise a boring head, behind which a cylindrical shield with a shield jacket and a shield tail is arranged. The shield has a smaller outer diameter than the drill head, so that there is no direct contact between the tunnel wall and the shield. When the tunnel boring machine has advanced a certain distance, the concrete elements are positioned in the shield tail at the edge of the shield. They are pressed against the direction of advance against the adjacent concrete elements attached last and, if necessary, connected to them. Several concrete elements together form a tunnel extension in the form of a ring over the entire circumference of the tunnel. The tunnel expansion will then be gradually built ring by ring.

The gap between a ring and tunnel wall is possibly filled with mortar, e.g. B. to prevent subsidence. For this purpose disclosed, for example WO 2005/0241863 A1 in the center of the concrete element an injection hole which is designed as a hole connecting the outer surface of the concrete element to the inner surface of the concrete element. After the individual concrete element has been positioned and connected to its neighboring concrete elements, mortar is injected between the concrete element and the tunnel wall via the injection hole. This prevents subsidence in the ground surrounding the concrete elements. In addition, the concrete element can be displaced and positioned by means of the injection hole by engaging a suitable tool.

This type of tunnel lining is also used, among other things, for the construction of sewer pipes, in particular of larger collecting pipes. As with other possible uses, increased demands are placed on the tightness of the tunnel cladding. The inside of the tubbing is sealed with a cladding so that no gases rising from the wastewater or possibly even the wastewater itself can get into the concrete via the tunnel walls and damage it (corrosion).

For one with concrete elements according to WO 2005/024183 A1 , WO 2011/085734 A1 , WO 2015/139807 A2 or WO 2017/008913 A1 covered tunnels, the protective layer of protective elements protects the concrete of the concrete elements from the effects of aggressive (eg corrosive) gases or liquids. Together with seals, the protective elements of the concrete elements of the cladding thus seal the tunnel lining or its concrete elements from the inside. The concrete element is prefabricated with the protective element, which means that sealing the cladding as a separate work step in tunnel construction, for example welding the joints between the protective elements / protective layers of adjacent concrete elements, is no longer necessary.

Out DE 3800630A1 , US6328501B1 , WO2005 / 024183A1 , WO 2011/085734 A1 , WO 2015/139807 A2 , WO 2017/008913 A1 and also off JP2004132002 it is known that the segments used for the tunnel lining are pre-produced, and that a cladding is placed on the inside of the segments during the production of the segments, through which, when the individual segments are assembled into rings, the tunnel wall is sealed against water, sewage and Gases takes place.

A protective layer is provided on the concrete element, which covers an inner surface of the tubbing opposite a convex outer surface. This protective layer exists according to DE 3800630 A1 made of metal. This protective layer exists according to WO 2005/024183 A1 made of fiberglass or polyethylene (PE), according to WO 2011/085734 A1 from polydicyclopentadiene (pDCPD), according to WO 2015/139807 A2 from a mixture of PE and pDCPD, or according to JP2004132002 made of a synthetic resin and in particular made of polyethylene (PE), polypropylene (PP), PVC, polyester or vinyl ester and is firmly anchored in the concrete by means of mechanical anchoring, so that an inseparable connection between the protective layer and the concrete is created. The protective layer is designed so that only the inside of the segment element is covered ( JP2004132002 ) or side surfaces of the concrete element are also partially included ( WO 2005/024183 A1 , WO 2011/085734 A1 , WO 2015/139807 A2 ). A A choice of material from the options mentioned above is also given for the protective elements according to the invention.

According to WO 2005/024183 A1 , WO 2011/085734 A1 , WO 2015/139807 A2 and WO 2017/008913 A1 a seal, which protrudes beyond the protective layer, is then provided on the side surface. The seal is made of an elastic material so that when the individual tubbings are put together for tunnel lining, the joints between the adjacent concrete elements are closed by the seal. Such a protective element seal with the function described above is also provided for the protective elements according to the invention. Alternatively, the joints can be closed by welding the individual protective layers provided on the inside of the concrete elements.

The concrete element itself is according to US 6328501 B1 and WO 2005/024183 A1 produced by means of formwork. A protective layer is placed on the bottom of the formwork in the formwork. Furthermore, if provided, protective layer elements are also placed on the side walls of the formwork. Furthermore, if provided, the formwork has a recess into which the seal is inserted. Then the concrete is poured into the formwork in conjunction with the reinforcement. After the concrete has hardened, the segment is used as a tunnel lining.

In practice it has been found that in the transition between protective layer and seal according to WO 2005/024183 A1 Leaks can always occur if sufficient care was not taken in the manufacture of the concrete element when inserting the seal into the formwork and / or when arranging the seal in relation to the protective layer. Strikes against this WO 2011/085734 A1 suggest that the protective element is made from an injection-moldable plastic and that a one-piece gas-tight connection is provided between the seal and the protective element, in that the seal is connected to the protective element by overmolding when it is manufactured. In WO 2015/139807 A2 part of the PDCPD of the protective element is replaced by at least one flat PE element. This is also provided for the concrete elements according to the invention or their protective elements.

If, for example, there is groundwater in the area of the tunnel, there is a risk that it will be under pressure or that there will be a corresponding pressure depending on the depth of the tunnel. If there are cracks in the concrete or if the groundwater penetrates through the concrete, this is on the inside of the protective layer / elements, so that this / this is pressurized and must be dimensioned accordingly in order to counteract a failure of the protective layer. This occurred in particular in tunnels with segments WO 2005/024183 A1 in which the anchorages of the protective element came loose from the concrete. Here against looked WO 2011/085734 A1 another dimensioning of the anchor. This is safe, but possibly leads to an increased effort in the production of the protective elements or the finished concrete elements.

If the protective elements are welded together, which is usually done by hand, attention must be paid to the quality of the weld seams. Here, too, there may be detachments.

In the case of a two-shell construction, in which an inner shell is applied to the segments on site, or in the case of welded protective elements, the entire ring may not be covered with a protective layer, but in the sole area the protective layer or the welding of the protective layer is left out in the area that does not dry out. The water that is present can then flow down to the sole on the side of the protective elements facing the concrete elements and then enter the tunnel there and flow off over it. This is possible if this area does not dry out so that the concrete does not corrode due to gases. Such a structure is not possible if the wastewater alone cannot be diluted, or if the wastewater alone is already so aggressive that the concrete is impaired.

An alternative solution for pressurized water looks WO 2017/008913 A1 in front. The protective section has at least one drainage element, for example an opening in the protective element or also a sleeve / an erector plug with openings, possibly with a closure element, through which a liquid from the first side of the protective section can pass through to the opposite side of the protective section facing away from the concrete element. Instead of reinforcing the anchoring of the protective element with respect to the concrete element, the existing groundwater is instead purposefully discharged through the protective element, thereby preventing pressure-related detachment. In this case, however, the gas tightness of the protective element must be guaranteed despite the drainage element.

According to the invention, an alternative possibility of draining the concrete elements is proposed. The solution according to the invention provides that at least one concrete element has at least one concrete element seal arranged separately from the protective element with a second sealing effect, which seals the joint gas- and liquid-tight against the rock, that the protective element seal has a lower sealing effect than the concrete element seal, that the tunnel lining there is drainage from a mountain surrounding the tunnel lining into a tunnel formed by the tunnel lining, that between the protective element seal and the concrete element seal there is water permeability from the concrete element into the joint, and that the drainage through the joint between the at least two concrete elements in the section takes place between the concrete element seal and the protective element seal (30) and through the protective element seal.

Surprisingly, it has been shown that this makes it possible to provide an adequate drainage option as protection against protective elements tearing off the concrete elements. At the same time, this makes it possible to provide adequate protection against corrosion if openings in the protective elements are not possible.

Another teaching of the invention provides that the concrete element seal is provided on the protective element at a distance from the protective element seal. This enables safe drainage out of the concrete element in a simple manner.

Another teaching of the invention provides that the concrete element seal is arranged in a recess in the concrete element. This enables a secure arrangement of the concrete element seal on the concrete element in a simple manner.

Another teaching of the invention provides that the protective section has at least one floor section or at least one floor section and at least one wall section. In this way, a sufficient protective element is provided in a simple manner.

Another teaching of the invention provides that the connecting element is an anchor structure, a honeycomb structure, a web, a pin and / or a surface element with openings. Another teaching of the invention provides that the connecting element is projections which preferably consist of the same plastic as the bottom section and / or wall section. It is also advantageous that the protective section is connected in one piece to the at least one connecting element, the one-piece connection preferably being produced by injection molding of the plastic. In particular, surface elements, such as honeycomb structures or surface sections with through openings, allow the protective element to be anchored particularly well to the concrete element over the entire surface of the protective element. The additional provision of pins or the like, which, if necessary, extend further into the concrete of the concrete element, an increased punctual increase in the holding force can be achieved.

Another teaching of the invention provides that the gas-tight and liquid-tight connection between the protective section and the protective element seal is injection molded. Another teaching of the invention provides that the protective element seal with the protective section is produced by injection molding with at least one plastic. This makes it possible to limit the injection molding essentially to the direct connection of the base section to the protective element seal. By connecting the seal and the connecting elements to the protective section, a liquid-tight and gas-tight one is achieved in a particularly simple manner Connected. Injection molding ensures that the protective elements are manufactured with a consistently high quality, so that the protective effect of the protective element in relation to the finished concrete element is particularly high and of consistently high quality, regardless of the manufacturing process of the concrete element. The protective element is shaped in such a way that, in relation to the seal, an enclosure of the sealing material with the injection molding material, which is provided on at least three sides, is provided.

Injection molding is understood here to mean all processes that can be subsumed under injection molding, i.e. processes in which one or more thermoplastics / thermosets / elastomers, for example as polymers or monomers, are introduced into a mold alone, individually, one after the other or at the same time (for example Overmolding / overmolding or multi-component injection molding), or in which monomers are processed that only become polymers in the injection mold (e.g. reaction overmolding).

Another teaching of the invention provides that the plastic is a polydicyclopentadiene (pDCPD), preferably high temperature resistant, a resin into which glass fibers are preferably introduced, or a thermoplastic, preferably PE. With this plastic, a high product speed can be achieved due to the fast processing properties. At the same time, there is a particularly high level of resistance in use.

Another teaching of the invention provides that the at least two concrete elements are gas-tight with respect to the inside of the tunnel through the provision of the one protective element in each case. In this way, a high corrosion resistance of the tunnel lining is achieved in a simple manner.

Another teaching of the invention provides that the tunnel lining is constructed in two parts, with an inner concrete element on which the protective element is arranged, and an outer concrete element on which the concrete element seal is arranged. It is advantageous that between the Concrete elements a joint, preferably concentric, is provided through which a fluid flow can take place. Another teaching of the invention provides that the joint is filled with a liquid-permeable filler material. It has been shown that in this way, in a particularly simple manner, should a two-part tunnel lining be necessary, a simple drainage option is provided, with a high level of corrosion resistance being achieved at the same time in a simple manner.

Another teaching of the invention provides that, for example, the bottom and / or the wall section essentially consists of a film, a plate or a sheet, which is preferably connected with connecting elements, and / or is formed from a further plastic, for example PE . These are particularly inexpensive plastics. Components from these, such as plates, webs or foils, can be produced locally on site, so that there is no need for considerable transport costs and possibly also storage costs for the finished products.

In addition, another teaching of the invention provides that additional drainage elements can be provided in the flat sections of the protective elements. This is advantageous if the drainage according to the invention should not be considered sufficient when dimensioning the tunnel lining.

Another teaching of the invention provides in this context that a ceiling element is also provided, so that a hollow body is produced, into which the concrete and, if necessary, reinforcement is then introduced during injection molding. This is particularly advantageous if the outside of the concrete element must also be protected against aggressive water in the mountains.

The invention is explained in more detail below with reference to drawings.

Fig. 1

eine geschnittene Darstellung einer ersten Ausführungsform eines erfindungsgemäßen Tunnelausbaus mit Betonelementen mit Schutzelement,

Fig. 2

eine geschnittene Darstellung einer zweiten Ausführungsform eines erfindungsgemäßen Tunnelausbaus mit Betonelementen mit Schutzelement, und

Fig.3a - 3d

Prinzipskizzen in Schnittansichten alternativer Ausführungsformen des Schutzelements,

Show:

Fig. 1

a sectional view of a first embodiment of a tunnel lining according to the invention with concrete elements with protective element,

Fig. 2

a sectional view of a second embodiment of a tunnel lining according to the invention with concrete elements with protective element, and

Fig. 3a-3d

Basic sketches in sectional views of alternative embodiments of the protective element,

In a first embodiment of a tunnel lining 300 according to the invention, a lining ring made of concrete elements 10 (tubbings) ( Fig. 1 ) intended. The concrete element has a convex upper side 11 and an opposite underside 12 (in Fig. 1 covered by a protective element 20). The protective element 20 is arranged on the underside 12 of the concrete element 10.

The concrete element 10 has recesses 14 on its wall sections 13, which are not covered by the protective element 20, for example. Concrete element seals 50 are arranged in the recesses 14. These have a sealing surface 51 which, when the individual concrete elements 10 are assembled, either meets another wall section 13 or another sealing surface 51 of a concrete element seal 50. Inside, the concrete element seal 50 has chambers 52, for example. When assembling the concrete elements 10, the elastic plastic of the concrete element seal 50 is deformed and the chambers 52 are compressed. Opposite to the sealing surface 51, holding projections (not shown) can optionally be arranged which engage in the concrete 16 after it has been poured.

In this embodiment, the protective element 20 has a bottom section 21 and wall sections 22, 23. A receiving area 29, in which a protective element seal 30 is arranged, is provided on these wall sections 22, 23. The connection between seal 30 and protective element 20 is made, for example, by injection molding.

Between the protective element seal 30 and the concrete element seal 50, a spacing 15 is provided which is not covered by the protective element 20.

Alternatively, the concrete element 10 can also have only one protective element 20 with a bottom section 21 (not shown) on which the protective element seal 30 is arranged in a gas- and liquid-tight manner, for example by injection molding.

The protective element 20 has a bottom section 21, on the outer sides of which wall sections 22, 23 are arranged essentially at right angles, but also in any other arrangement. To produce a holding connection between the protective element 20 and the concrete element 10, the inside of the floor section 21 has holding elements 17, for example pins. Alternatively and not shown, webs can also be arranged parallel to an outer wall and webs to the outer wall arranged at right angles thereto. The webs can, for example, be provided with openings through which concrete 16 can pass and thus produce a particularly good holding connection after hardening.

The bottom section 21 has a second flat section 28, which can consist of a PE film, for example. This second section can extend over the entire base section 21 or only parts thereof. It is preferably connected to the rest of the protective element 20, in particular the first section 25, which can form part or the entire wall section 22, 23, by means of injection molding.

The protective element seal 30 consists of an elastic plastic. The seal 30 has a sealing surface 31 which, when the individual concrete elements are assembled, meets either another concrete surface or another sealing surface 31 of a protective element seal 30. In the interior, the protective element seal 30 has chambers 32. When assembling the concrete elements 10, the elastic plastic of the protective element seal 30 is deformed and the chambers 32 are compressed. Opposite to the sealing surface 31 holding projections 33 are arranged, which in the plastic Wall sections 22, 23 of the protective element 20 engage. This and the adjacent side walls of the protective element seal 30 combine with the plastic of the protective element during injection molding or are enclosed by this in a gas-tight manner. According to the invention, the protective element seal 30 has a sealing effect that is smaller than the sealing effect of the concrete element seal 50 but is sufficiently great that no gases or liquids can pass from the tunnel interior 100 through the protective element seal 30 and, for example, can get into the joint and then with the Concrete 16 can come into contact.

A protective element 20 as shown in Fig. 1 is shown can be made, for example, by injection molding. Alternative embodiments are in Fig. 1 and 3a to 3d shown.

Figures 3a to 3d show alternative embodiments of the protective element 20 with a view to the fact that the protective element 20 or the floor section and / or the wall section are at least partially made of a flat section 28 from prefabricated semi-finished products such as webs with projections arranged thereon. Figures 3a to 3d show various exemplary ways of connecting the second section 28 to a first section 25, which was produced, for example, by injection molding. This connection can be made abruptly ( Figures 3a, 3d and 3c ) or the second section 28 is joined by the first section 25 on one side (not shown) or on both sides ( Fig. 3d ) encompassed. In Figure 3b the flat element forming the second section 28 is provided not only as a component of the bottom section 21, but also as a wall section 22, 23. The intermittent joining, as in Figures 3a, 3d and 3c shown, has surprisingly proven to be sufficient in particular in the connection of PE as a flat element and pDCPD as an injection-mouldable plastic of the first section 25. Depending on the requirements placed on the protective element, it is also possible to provide several flat sections, if necessary made of different materials, which are then connected to one another via several first sections 25 via the or several different injection-mouldable plastics. This applies to both the floor section 21, wall section 22, 23 and ceiling sections.

Not shown is the possibility of providing further drainage openings on the first and / or second sections 25, 28 and providing them in these drainage elements.

The tunnel lining 300 according to the invention is formed by assembling the concrete elements 10 to form a ring on the rock 200 and arranging several rings to form an expansion. Joints 40 are present between the concrete elements 10 as a result of the assembly. These joints are closed by the concrete element seals 50 on the mountain side in such a way that their sealing effect is greater than the groundwater pressure, so that no groundwater or other pending liquids can enter the joints 40 behind the concrete element seal 50.

On the upper side 11 of the concrete element 10 there is groundwater or groundwater under pressure in the rock 200, depending on the depth of the tunnel in the ground. This acts in the direction of arrow A on the tunnel lining 300 according to the invention. The concrete element seal 50 is designed in such a way that its sealing effect prevents the groundwater from penetrating into the joint 40 behind the concrete element seal 50. If there are cracks in the concrete 16 in the event of damage or if the groundwater penetrates through the concrete 16 in the event of damage, this may be present on the underside 12 of the concrete element 10 on the inside of the protective element 20. It can move between the protective element 20 and the concrete element 10 and, depending on the design, passes in the direction of arrow B through the distance 15 not covered by the protective element 20 and through it into the joint 40 and to the rear of the protective element seal 30. However, it is not necessary to reach the inside of the protective element 20. The water can also get directly into the joint 40 and to the rear of the protective element seal 30 in the direction of arrow B.

Since, according to the invention, the sealing effect of the protective element seal is smaller than the existing groundwater pressure / liquid pressure, the water / liquid passes through the protective element seal 30 in the direction of arrow C and reaches the tunnel interior 100.

In a first embodiment of a tunnel lining 300 according to the invention, two concentrically constructed lining rings made of concrete elements 10a, 10b (tubbings) ( Fig. 2 ) intended. The first expansion ring is composed of the concrete elements 10a. On their wall sections 13a, these have a recess 14 in which a concrete element seal 50 is arranged. There are joints 40a between the concrete elements 10a. The second extension ring is then erected from concrete elements 10b, either after the construction of the first extension ring has been completed or only with a time delay, which have protective elements 20 with a protective element seal 30 as described above on their underside 12. There are joints 40b between the concrete elements 10b.

Between the concrete elements 10a and 10b, a concentric joint 41 is provided after assembly, which is filled with a filling material 42, preferably water-permeable.

The drainage is also carried out as described above. There is only one further possibility for the groundwater / liquid to flow in the direction of arrow D in the joint 41 through the filler material 42 to the joint 40b. List of reference symbols 32 chamber 10 Concrete element 33 Retaining protrusion 10a outer concrete element 40 Gap 10b inner concrete element 40a outer joint part 11 Top 40b inner joint part 12th bottom 41 Gap 13th Wall section 42 filling material 13a outer wall section 50 Concrete element seal 13b inner wall section 51 Sealing surface 14th deepening 52 chamber 15th distance 16 concrete 100 Inside of the tunnel 17th Retaining element 200 Mountain range 20th Protective element 300 Tunnel lining 21 Floor section 22nd Wall section A. Upcoming groundwater 23 Wall section B. Direction of flow in the concrete element 25th first section C. Direction of flow into the interior of the tunnel 28 second part D. Direction of flow in joint 41 29 Recording area 30th Protective element seal 31 Sealing surface

Claims (10)

1. Tunnel lining composed of at least two concrete elements (10) each having at least one protective element (20) connected to the concrete element, wherein the protective element (20) has a protective portion which has a first side which faces the concrete element (10) and on which there is provided at least one connecting element (17) for producing a retaining connected between the protective portion and the concrete element (10), wherein the protective portion consists of at least one plastic, wherein the protective element (20) has at least one protective element seal (30) which is connected to the protective portion (20), wherein the connection to the protective portion (20) is gas-tight and liquid-tight, wherein a joint (40) is present between the at least two concrete elements (10) arranged to form the tunnel lining (300), wherein the joint (40) is sealed in a gas-tight and liquid-tight manner with respect to the tunnel interior (100) by at least one protective element seal (30) having a first sealing action, characterized in that at least one concrete element (10) has at least one concrete element seal (50) having a second sealing action that is arranged separately from the protective element (20) and seals the joint (40) in a gas- and liquid-tight manner with respect to the rock (200), in that the protective element seal (30) has a lower sealing action than the concrete element seal (50), in that the tunnel lining is provided with drainage from a rock surrounding the tunnel lining into a tunnel formed by the tunnel lining, in that water permeability from the concrete element in the joint (40) exists between the protective element seal (30) and the concrete element seal (50), and in that the drainage through the joint (40) between the at least two concrete elements (10) occurs in the portion between the concrete element seal (50) and the protective element seal (30) and through the protective element seal (30).
2. Tunnel lining according to Claim 1, characterized in that the concrete element seal (50) is provided at a distance from the protective element seal (30) on the protective element.
3. Tunnel lining according to Claim 1 or 2, characterized in that the concrete element seal (50) is arranged in a depression (14) in the concrete element (10).
4. Tunnel lining according to one of Claims 1 to 3, characterized in that the protective portion has at least one bottom portion (21) or has at least one bottom portion (21) and at least one wall portion (22, 23).
5. Tunnel lining according to one of Claims 1 to 4, characterized in that the gas-tight and liquid-tight connection between the protective portion and the protective element seal is injection-moulded.
6. Tunnel lining according to one of Claims 1 to 5, characterized in that the plastic is a polydicyclopentadiene (pDCPD), preferably with high-temperature resistance, a resin, into which preferably glass fibres are incorporated, or a thermoplastic, preferably PE.
7. Tunnel lining according to one of Claims 1 to 6, characterized in that the at least two concrete elements (10) are gas-tight with respect to the tunnel interior (100) through the provision of the respective one protective element (20) each.
8. Tunnel lining according to one of Claims 1 to 7, characterized in that the tunnel lining (300) is built up in two parts with an inner concrete element (10b), on which the protective element (20) is arranged, and an outer concrete element (10a), on which the concrete element seal (50) is arranged.
9. Tunnel lining according to Claim 8, characterized in that a joint (41) through which a liquid flow can occur is provided between the concrete elements (10a, 10b).
10. Tunnel lining according to Claim 9, characterized in that the joint (41) is filled with a liquid-permeable filler material.

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