US3483704A - Tunnel liner and method of making same - Google Patents

Description

Dec. 16, 1969 J. R. TABOR 3,483,704

TUNNEL LINER AND METHOD OF MAKING SAME Filed Dec. 16, 1966 2 Sheets-Sheet 1 f INVENTOR' JOHN R. mam

Dec. 16, 1969 J. R. TABOR 3,483,704

TUNNEL LINER AND METHOD OF MAKING SAME Filed Dec. 16, 1966 2 Sheets-Sheet 2 JOHN R. 734 80/? United States Patent O 3,483,704 TUNNEL LINER AND METHGD OF MAKING SAME .lohn R. Tabor, 3460 Spruce St., Racine, Wis. 53403 Filed Dec. 16, 1966, Ser. No. 602,326 Int. Gl. E2141 11/08; E04!) 1/32; E94: 1/10 US. Cl. 61-45 16 Claims ABSTRACT OF THE DISCLOSURE A tunnel liner and method of making same having a plurality of blocks in a circle with wedge means between the blocks for radially expanding the circle upon axial displacement of the wedge means. Alignment and securing dowels, and also waterproofing pieces are disposed betwen the blocks for assembly, strength, and waterproofing of the liner.

BACKGROUND OF THE INVENTION This invention relates to a tunnel liner and method of making same. The liner disclosed utilizes concrete blocks which are disposed in a circle and are particularly useful in lining the wall of a tunnel in the ground.

The prior art has employed concrete blocks for lining ground tunnels, and these blocks are commonly arranged to have tapered or wedge-shaped faces so that when the blocks are disposed in their circular form, axial force on the blocks will cause the circle to expand to the diameter of the tunnel cut in the ground. Thus, a tunneling machine is commonly provided with a forwardly located cutter and a rearwardly located skirt. It is common practice to initially dispose the blocks in a circle of a circumference less than that of the full circumference of the cut in the ground. Then the blocks are expanded in their circular pattern so that they have a circumference comparable to that of the ground, and the blocks thus provide a liner which is in abutment with the ground and thereby gives desired support. Further, the radial expansion of the blocks is known to have been accomplished by applying a force on the blocks in a direction axially of the circle of blocks. US. Patent No. 1,336,789 shows these features. However, that type of prior art requires a block of a complex shape which is difiicult to manufacture and to handle without damage to the blocks. Where that block of the prior art is made exclusively of concrete, it is subject to breakage when the blocks are placed in abutment and are forced together. While concrete blocks are capable of resisting large compressive forces, they are nevertheless susceptible to chipping and cracking when subjected to concentrated forces on only a line or a limited area of the block, and this is likely to be the case with the prior art blocks mentioned. Further, the axial forces are applied directly to the prior art blocks, and, in the instance of the one prior patent cited above, the force is applied to only half of the blocks in any one course of blocks, as there is no continuous planar wall of blocks for receiving the surface applying the axial force.

Further, in the prior art where only the concrete blocks are in direct abutment with each other, the tunnel is subject to water leaks, unless it is elaborately treated .with extensive grouting between the joints. In the present invention, the tunnel is arranged in a waterproof manner at the same time that it is assembled, and such waterproofing is even of a self-sealing nature where intervening pieces of wood or like material are employed between the blocks so that the wood can absorb the forces which might otherwise damage the block and it can water-proof by expanding when it is moist and is thereby self-sealing. Still further, the intervening pieces are utilized for assembly in assisting the alignment of ice the blocks, and they are also utilized for reinforcing in the strength of the liner in final assembly as they are available for resisting forces tending to shear the liner as well as absorbing the forces axially of the liner. Further, where resilient pieces are utilized between the concrete material of the blocks, such as where wooden dowels and seal pieces are used, the entire liner is more shockproof and is also more capable of adjusting to different required positioning due to any ground shifting or the like. So the intervening resilient pieces are available for both the absorbing of shock when the liner is finally assembled, and also for cushioning between the concrete material of the blocks when the liner is being assembled so the blocks will not be damaged by any concentrated stress applied to the concrete material, such stress being notorious for cracking concrete blocks.

Still further, it is common practice to stagger blocks which form a wall, and, in this instance, alignment means, such as dowels, are provided for the staggering which must follow the requirements of the dowels according to positions and sizes of the dowels. In accomplishing this, the dowels are shown to be disposed in certain positions and are of at least two different sizes so that they must mate with the adjacent block in a manner which assures the desired staggering of the blocks. This feature, and the aforementioned features of this invention, all provide a means and method for a tunnel wall which is easy to erect, can be erected at a pace which is comparable to the speed at which the tunneling machine can operate, it reduces the need for reinforcing means such as steel beams, and it reduces the cost of constructing a tunnel having the strength characteristics of the concrete block type of tunnel. Also, it provides both a means and a method for constructing a concrete block tunnel wherein the force required for expansion of the circumference of the tunnel need not be applied directly to the concrete block. Instead, the force can be applied to pieces of wood or like material inserted between the blocks, and these pieces are more capable of receiving large forces without damaging the wood pieces or the concrete block.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a top plan view of one embodiment of a block of this invention, and FIG. 2 is a front elevational view.

FIG. 3 is a plan view of a fragment of a wall in assembled position.

FIG. 4 is an end axial view of the ground tunnel and the tunnel wall prior to the expansion of the wall.

FIG. 5 is an elevational view of the left hand face of the block in FIG. 2.

FIG. 6 is a side view of a pin disposed between the blocks.

FIG. 7 is an end elevational view of a dowel disposed between the blocks, and FIG. 8 is a side elevational view of FIG. 7.

FIG. 9 is a top plan view of another embodiment, and FIG. 10 is a front elevational View.

FIG. 11 is a wall fragment plan view of this other embodiment.

DESCRIPTION OF THE METHOD AND PREFERRED EMBODIMENTS A block 10 is shown to be elongated and arcuate, in its display in FIG. 2, and the block is preferably made of concrete. It has oppositely disposed planar faces 11 and 12, and end walls 13 and 14. Dowels 16 and 17 are cast into the block to project from the wall 11, as shown in FIG. 1. Also, a water-proofing piece 18, which may be a strip of wood, is disposed in the block to project from the face 12 as shown in FIG. 1. The strip 18 is disposed in a groove 19 in the block 10, and there may be three 3 such strips 18 in each face 11 and 12, as three grooves 19, 21 and 22 are provided in each face 11 and 12, as shown.

The end walls 13 and 14 have tapered openings 23 and 24 formed therein, and with the openings being shown to be half-circles. Finally, the block has tapered openings 26 and 27 formed in the face 12. Thus the entire block 10 can be cast in concrete material, and the holes, openings, grooves, and the like can all be cast directly into the material, and the dowels 16 and 17 can also be cast into the concrete.

FIG. 3 shows the assembly of the blocks in a tunnel liner, and it will be noted that the blocks are staggered so that there is no extended joint line, and the liner is therefore of optimum strength and minimum water susceptibility. Further, it will be noted that every two adjacent blocks 10 have a tapered pin 28 disposed therebetween, and the pin 28 may be made of wood. Likewise, the dowels 16 and 17 may be made of a core 29, of wood, and a casing 31 of metal. These dowels 16 and 17 may also be tapered to be smaller at the projecting ends, as shown in FIG. 1. The liner as shown in FIG. 3 is indicated to be in the expanded condition, and that is accomplished by placing a force axially of the circularly disposed blocks, as shown in FIG. 4. Thus the force for expansion is applied to the tapered pins 28 which are disposed in the block tapered holes 23 and 24, and axial displacement of the pins 28 relative to their blocks 10 will cause the blocks to spread apart with respect to each other, as indicated in the spacing designated 32 in FIG. 3. This spacing might therefore exist between every two adjacent blocks 10 so that the circumference of the assembly of a plurality of blocks 10, as shown in FIG. 4, would be enlarged from that shown in FIG. 4. until it is the size of the circumference designated 33 of the tunnel in the ground indicated at 34 in FIG. 4. This is of course the desired final disposition of the blocks 10, so that they are in abutment with the tunnel wall or circumference 33 to give maximum support to the tunnel wall 33.

Of course the blocks 10 are assembled in the tunnel wall one by one, and apparatus (not shown) may be used for positioning the blocks in their respective positions and courses to construct the cylindrical tunnel of blocks.

To cause the radial and circumferential expansion described, the pins 28 have their ends 36 of a diameter comparable to the diameter of the conical hole formed by the half- circles 23 and 24 at the large end, that is at the wall 12. Then when the pins 28 are axially displaced, they will of course cause the wall expansion desired. Suitable jacks (not shown) can be applied to the pins 28 at their large ends 37 to force the pins between the adjacent blocks 10, and slightly therebeyond, as shown. Thus the length of the pins 28 is comparable to the width of the blocks 10 from faces 11 to faces 12. This means the pin ends 36 protrude, as shown in the first course of blocks shown in FIG. 3, and the pin ends 37 are countersunk, as most clearly shown in the last or lower course of blocks shown in FIG. 3.

Dowel 17 is thus shown constructed as mentioned, that is, with the dowel being made of a wood core 38 and a metal casing 39. The dowel 17 is also tapered, and in both dowel 16 and 17 the cores are of wood and are shown to extend slightly beyond the metal casings. Thus when the blocks 10 are assembled as shown in FIG. 3, and the axial forces applied to the pins 28, the dowels 16 and 17 are respectively received in the holes 27 and 41 where 41 is a hole formed by the block holes 23 and 24 and cleared by the countersinking of the pins 28, as mentioned. Since the dowels 16 and 17 are of different diam eters, the assembly of the tunnel from course to course is guaranteed to be in proper relationship. Further, the pin projecting ends 36 are received in the tapered openings 26 in the adjacent course of blocks. In all instances of these various dowels and pins extending into their respective op n g o ho s, t e fit s such. tha h d9 a P l will easily commence insertion, and, upon forcing axially of the tunnel, the projecting dowels and pin ends will become some what compressed in that the fit is tight in final assembly. Thus the resilient or wood material is utilized so that it can be compressed for securing the courses together and creating a structure having maximum resistance to damaging forces. Also, the wood strips 18 disposed between the block faces 11 and 12 on adjacent blocks 10 are available for slight compression in the assembly of the wall courses, and these strips provide water-proofing between the courses. Thus the projection of the wood strip 18, as shown in FIG. 1, would insert into the mating groove 19 on the adjacent 'block 10, and specifically on the wall 11 of that adjacent block. When these wood pieces 18, and also the wood pins and dowels described, are subjected to moisture, they tend to expand and thereby enhance their water-proofing characteristics, and they even enhance the strength of the tunnel liner.

Thus FIG. 3 shows that a first course of blocks, generally designated 42, may be set up in a ring or circular arrangement, and subsequent courses 43 through 46 would also be located. Each course could have its pins 28 subjected to an axial force designated A in FIG. 3 and applied by power means such as a jack which is not shown. The force A would be applied to the pins prior to the assembly of the next adjacent course of blocks. This will also cause the dowels 16 and 17 to become firmly seated in their respective mating holes, and the metal casings on the dowels 16 and 17 are available for resisting forces tending to shear the courses apart. The dowels 16 and 17 are therefore disposed across the joint be tween courses, and this is a plane designated 47 in FIG. 3, and it will be noted that the plane 47 forms an endless and continuous wall by the block faces 12 so that any assembly forc transmitted to the respective courses is equally transmitted to the entire course. The dowels 16 and .17 are shown to have the split casings 31 and 39 so that these casings can contract to the extent neces* sary to be snug within their respective holes on the adjacent blocks, as their respective wood cores 29 and 38 are slightly crushed to thereby absorb the assembly forces and be desirably snug and provide a firm grip between the courses in the final assembly.

So that no special block construction is required for gripping and raising the blocks into the position shown in FIG. 4, block placer apparatus of a suction type which would grip the blocks, could be used. This would therefore eliminate the need for any special additional grip means on the block or any hooks applied to the blocks or any enlarged openings in the blocks for gripping same, and the blocks therefore remain at maximum density and strength. Still further, the jack force A may be applied by the cutting machine itself, in any Well-known manner. So the direction of machine cutting in tunneling is shown by arrow B in FIG. 3, and jack forces A are machine reaction forces. The method steps hav been described in the foregoing, and they may be carried out by hand. The blocks could be placed by hand, and the pins 28 dis placed by hand to expand the ring of blocks, shown in IgG. 4, into the crescent-shaped void space designated Of course the block could be made of material other than concrete, and it could be made of somewhat different shape and with different dowels and holes. FIGS. 9, 10 and 11 show another embodiment of the block which can be used in the manner described in connec tion with block 10. A block 51 is shown to be provided with one large dowel 52 being of a tapered form and having a center core 53 which is of a resilient material, such as wood. The dowel 52 also has a metal or hard casing 54 which is split, as shown, so that again it will compress and even crush the core 53 in the assembly, as de scribed. A small tapered hole 56 is provided in the block 51, and it will be noted that the dowel 52 is on one block ew 5 d e s 56 son t e oppa i e blac e The end walls 59 and 61 of the block 51 have tapered openings 62, and these openings are available for receiving wedge means, such as the pin 28.

The block 51 also has grooves 63 which extend along the faces 57 and S and between the openings in the blocks, and these grooves receive self-sealing water-proofing material, such as wood strips 64 and 66. It will therefore be apparent that when the blocks are assembled in courses, such as the three courses 67, 68 and 69 of FIG. 11, the strips provided on the block face 58 will be inserted into the openings 63 on the adjacent course of blocks and along the faces 57 of this adjacent course.

Also, as shown in FIG. 11, the pins 28 are substantially the size and shape necessary to radially expand the ring or circle of blocks 51. Thus the pins 28 are of a length approximately equal, at least, to the thickness of the block 51. Then the pins can again be countersunk in assembly, as shown in FIG. 11, and their ends 36 will project beyond the planar wall or plane between the courses of blocks. The projecting pin end 36 will then be received in the hole 56. In this manner, the blocks are aligned, secured, and of course staggered as shown in FIG. 11, as desired. Also, the tapered dowel 52 is then received in the hole designated 71, and this is the hole or opening provided by the countersinking of the pin 28. Again, the diameter of the pin 28 is larger than the corresponding cross-section of the adjacent holes 62 for the wedging described.

While specific embodiments and method of making same have been shown and described, it should be obvious that certain changes could be made therein and the invention should therefore be determined only by the scope of the appended claims.

What is claimed is:

1. In a tunnel liner including blocks adaptable to hav a plurality of said blocks disposed in an end-to-end circular relation and in face-to-face circular courses to form a circular lining for a tunnel in the ground, and having wedge means disposed to be operative between said blocks for radially displacing said blocks by a force axial of the circle for expanding the circle, the improvement which comprises the opposite ends of said blocks having recesses tapered at the angle which is on said wedge means and with said blocks being adapted to be arranged in courses with each having an endless planar end wall and with said wedge means being located in said recesses at said opposite ends of said blocks and at the joints therebetween and with said wedge means being pieces separate from said blocks to expand said circle upon displacement of said wedge means relative to said blocks and axially of said circle and upon forcing said planar end wall toward the adjacent one of said courses, and with said angle on said recesses and said wedge mens being tapered in the axial direction of said tunnel.

2. The subject matter of claim 1, wherein said wedge means is a tapered wooden pin for radially displacing said blocks upon axial displacement of said pins with respect to said blocks.

3. The subject matter of claim 2, including one face of said blocks having holes therein and dowels extending from the face of said blocks on the side opposite said one face, and wherein pins are countersunk with respect to said blocks at one end of said pins, and said pins extend beyond said blocks at the other end of said pins, and said dowels being mated in the openings provided by the countersinking, and the extensions of said pins being mated in said holes, all for aligning and securing said blocks and said courses together.

4. The subject matter of claim 1, including pieces disposed between said blocks at the faces thereof between said courses, and said pieces and said wedge means being of a material which is resilient and is self-sealing waterproofing respectively with said faces and said ends of said blocks.

5. The subject matter of claim 1, including mated members and holes on respective adjacent ones of said blocks in adjacent course mated together for aligning and securing said courses of said blocks together.

6. The subject matter of claim 5, wherein said members are tapered wooden dowels and said holes are of a crosssectional size to be snug with said dowels upon forcing said courses of said blocks toward each other.

7. The subject matter of claim 5, wherein said members are a combined wooden core and an outer casing and arranged to form a tapered dowel, and said holes are of a cross-sectional size to separately snugly receive said dowels to cause side dowels to be radially compressed and to thereby grip said blocks together when said blocks are displaced to axially force said dowels into said holes.

8. The subject matter of claim 7, wherein said dowels and said holes are both mutually tapered for ease of entrance of said dowels into said holes and for radial compression of said dowels upon axial movement of said dowels into said holes.

9. The subject matter of the combination of claims 1, 2, and 5.

10. The subject matter of claim 5, wherein said block is arranged to be asymmetrical by having said members on each of said blocks of different sizes for necessitating staggering of said blocks between said courses.

11. In a tunnel liner including blocks adaptable to have a plurality of said blocks disposed in an end-to-end circular relation and in face-to-face circular courses to form a circular liner for a tunnel in the ground, and having wedge means disposed to be operative between said blocks for radially displacing said blocks by a force axial of the circle for expanding the circle, the improvement which comprises said wedge means being disposed between the ends of said blocks at the joints of said liner and being of a material which is resilient and is self-sealing water-proofing with said ends of said blocks, said wedge means extending beyond the thickness of said course of blocks, and said blocks having openings therein for reception of the extending ends of said Wedge means.

12. In a method of lining a tunnel with blocks disposed in a circle to form the tunnel wall and expanding the circle by a force applied to said wall axially of said circle, the improvement which comprises the steps of disposing said blocks in a circle and having tapered recesses in both opposite ends of each of said blocks and with the taper being oriented in the direction of the axis of said circle, placing wedge-shaped pieces in said tapered recesses between the ends of every two of adjacent ones of said blocks, and forcing all said wedge-shaped pieces along said tapered recesses and axially of said circle and thereby increasing the diameter of said circle by forcing all said blocks away from each other and radially outwardly under the influence of the axial force.

13. The method claimed in claim 12, including the steps of arranging said blocks with projecting dowel pins and mating holes and arranging said dowel pins and said holes in said blocks on their respective faces which are parallel to the right-angle radial plane of said circle, and forcing said dowel pins and said holes into snug mating relation by the axial force applied.

14. The method claimed in claim 12, including the step of compressing a compressible and self-sealing waterproofing iece between the faces of said blocks by the axial force applied.

15. The method claimed in claim 13, including the step of compressing a compressible and self-sealing waterproofing piece between the faces of said blocks by the axial force applied.

16. The method claimed in claim 12, including the step of forming said tapered recesses and said wedge-shaped pieces in a conical shape for forcing said wedge-shaped pieces in both the radial and tangential directions on said blocks by the axial force applied.

(References on following page) References Cited UNITED STATES PATENTS Butler 61-45 McGowan 287-127 ORourke 61-45 Coyle 61-43 ORourke 61-45 Ruskin 287-127 Phipps 52-396 8 FOREIGN PATENTS 724,853 2/1955 Great Britain.

JACOB SHAPIRO, Primary Examiner US. Cl. X.R.

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