JP2006159581A - Combined segment and its manufacturing method - Google Patents

Combined segment and its manufacturing method Download PDF

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JP2006159581A
JP2006159581A JP2004353469A JP2004353469A JP2006159581A JP 2006159581 A JP2006159581 A JP 2006159581A JP 2004353469 A JP2004353469 A JP 2004353469A JP 2004353469 A JP2004353469 A JP 2004353469A JP 2006159581 A JP2006159581 A JP 2006159581A
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plate
steel
welding
segment
main girder
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JP4541858B2 (en
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Hiroaki Nakayama
裕章 中山
Masato Miyake
正人 三宅
Yoshinori Fujii
義法 藤井
Seishi Yoshino
清史 吉野
Tsutomu Oba
務 大場
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TOKYO EKON KENTETSU KK
Nippon Steel Corp
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Nippon Steel Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a combined segment constituted by integrating an internal reinforced concrete structure and an outer shell from an aspect of strength. <P>SOLUTION: Rod-shaped steel materials 4 are installed on a steel shell equipped with main beams 1, joint plates 5, a skin plate 3 and longitudinal ribs 2 having opening parts 7 so as to cross longitudinal ribs 2 and the steel shell is filled with padding concrete 6 to form a combined segment. In this combined segment, the longitudinal ribs 2 are incorporated in and welded to the skin plate 3 on which the main beams 1 are temporarily placed at predetermined attaching positions, the rod-shaped steel materials 4 are subsequently inserted in the longitudinal ribs 2 to form a member composed of the skin plate 3, the longitudinal ribs 2 and the rod-shaped steel materials 4, this member is integrally molded along with the outer shell composed of the main beams 1 and the joint plates 5, the skin plate 3 and the longitudinal ribs 2 by welding and concrete 6 is cast in the formed outer shell. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、シールドトンネル内に覆工体として用いられるセグメント及びセグメントの製造方法に関し、特に、鉄筋コンクリート構造を鋼板等で覆って一体化してなる合成セグメント及びその製造方法に関するものである。   The present invention relates to a segment used as a lining body in a shield tunnel and a method for manufacturing the segment, and more particularly to a synthetic segment formed by covering a reinforced concrete structure with a steel plate or the like and integrating the same.

内部に鉄筋コンクリート構造を有する合成セグメントの製造方法には、例えば特許文献1に示されているように、外周の6面を構成するセグメント外殻のうち、トンネル外方面に配置される面の板を除く残りの5面の板で構成される外殻を初めに製作し、次にその外殻で形成される内部空間の中に鉄筋を配置し、その後外殻の残りの1面を最初の5面からなる外殻に被せて、最後に外殻の一部に空けた注入孔からコンクリートを打設する方法が知られている。   In the method of manufacturing a composite segment having a reinforced concrete structure inside, for example, as shown in Patent Document 1, a plate having a surface arranged on the outer surface of the tunnel among the outer shells of the segments constituting the outer six surfaces is used. An outer shell composed of the remaining five plates is first manufactured, and then a reinforcing bar is placed in the inner space formed by the outer shell, and then the remaining one surface of the outer shell is attached to the first five surfaces. A method is known in which concrete is cast from an injection hole that is finally covered in a part of the outer shell over a surface outer shell.

この工法では、外殻の板材に突起を取り付けることにより内部の鉄筋コンクリート構造と外殻との一体化を行っている。しかし当該技術では、内部に配設された鉄筋と外殻とが直接繋がっておらず、外殻を形成する板材の表面にある突起とコンクリートが接しているのみで、セグメントに外力として曲げ荷重が作用したときに、内部の鉄筋コンクリート構造と外殻とが一体化して外力に抵抗せず、セグメント全体が強度的に一体化していない。   In this method, the inner reinforced concrete structure and the outer shell are integrated by attaching protrusions to the outer shell plate. However, in this technology, the reinforcing bars arranged inside and the outer shell are not directly connected, and the projection on the surface of the plate forming the outer shell is in contact with the concrete, and the segment is subjected to a bending load as an external force. When acting, the internal reinforced concrete structure and the outer shell are integrated to resist the external force, and the entire segment is not integrated in strength.

また特許文献2にあるように、外殻の一部である主桁と一体化した縦リブの上に鉄筋を載せる製造方法が開示されている。鉄筋により、コンクリート内周部の強度を向上させ、コンクリートのクラックや脱落発生を回避する効果があるが、土水圧などによりセグメントに曲げモーメントが発生した場合、円弧状である鉄筋が引っ張られることで直線上になろうとし、鉄筋を被覆しているトンネル内空側のコンクリートが剥落する恐れがある。   Further, as disclosed in Patent Document 2, a manufacturing method in which a reinforcing bar is placed on a vertical rib integrated with a main girder that is a part of an outer shell is disclosed. Reinforcement has the effect of improving the strength of the inner periphery of the concrete and avoiding cracking and falling off of the concrete, but if a bending moment occurs in the segment due to soil water pressure, etc., the arc-shaped reinforcement is pulled. There is a risk that the concrete inside the tunnel covering the rebar will fall off trying to be straight.

内部の鉄筋コンクリート構造と外殻とが強度的に一体化した合成セグメントの製造方法として、特許文献3には、図1に示すように、予め棒状鋼材4を複数の縦リブ2の開孔7に配置し、棒状鋼材4と縦リブ2から成る梯子状部材を構築し、それを主桁1・継手板5からなる鋼殻内に配置し、縦リブ2両端部を主桁1に溶接により固定し、最後にスキンプレート3の周縁部を主桁1と継手板5に溶接して固定する方法が示されている。この方法によれば、棒状鋼材4が縦リブ2により拘束されているため、セグメントに荷重が作用したときでも棒状鋼材がコンクリート内から抜け出すことはなく、強度的に一体化した合成セグメントとなる。
特開平9−228787号公報 特開平8−277698号公報 特開2004−270276
As a method for producing a synthetic segment in which an internal reinforced concrete structure and an outer shell are integrated in a strong manner, Patent Document 3 discloses in advance a rod-shaped steel material 4 in openings 7 of a plurality of vertical ribs 2 as shown in FIG. Arranged to construct a ladder-like member consisting of bar steel 4 and vertical rib 2, placed in a steel shell consisting of main girder 1 and joint plate 5, and fixed both ends of vertical rib 2 to main girder 1 by welding Finally, a method is shown in which the peripheral edge of the skin plate 3 is welded and fixed to the main girder 1 and the joint plate 5. According to this method, since the bar-shaped steel material 4 is restrained by the vertical ribs 2, the bar-shaped steel material does not come out of the concrete even when a load is applied to the segment, and a combined segment is obtained in a strong manner.
Japanese Patent Laid-Open No. 9-228787 JP-A-8-277698 JP-A-2004-270276

上述した従来の技術では、特許文献1、2のような製造方法では、内部に配設する鉄筋はセグメント制作上支障とならず、容易に外殻内に収めることができるが、実際にトンネル内でセグメントとして使用されたとき、土水圧により発生する荷重に対して、内部の鉄筋コンクリート6と外殻が一体化して抵抗しない問題点があった。   In the conventional techniques described above, in the manufacturing methods as described in Patent Documents 1 and 2, the reinforcing bars disposed inside do not hinder segment production and can be easily accommodated in the outer shell. When used as a segment, there is a problem that the internal reinforced concrete 6 and the outer shell are not integrated and resist the load generated by the earth water pressure.

また特許文献3にあるような製造方法では、内部の鉄筋コンクリート構造と外殻とが一体化して外力に抵抗する構造体として機能するものの、鋼殻製造時に、内部に配置された棒状鋼材4と縦リブ2が障害となり、溶接ロボットのトーチが溶接箇所まで届かず製造の自動ライン化に載らないという課題があり、また手溶接するにも狭い範囲内での作業となり、作業効率が著しく悪いことが問題であった。   In addition, in the manufacturing method as disclosed in Patent Document 3, the internal reinforced concrete structure and the outer shell function as a structure that resists external force by integrating with the rod-shaped steel material 4 disposed inside the steel shell during the manufacturing of the steel shell. There is a problem that the rib 2 becomes an obstacle and the torch of the welding robot does not reach the welding point and cannot be put on the automatic production line. Also, it is a work within a narrow range even for manual welding, and the work efficiency is extremely bad. It was a problem.

溶接ロボットにて全て溶接が可能となるよう、スキンプレート3、縦リブ2、主桁1、継手板5、外縁側棒状鋼材15から成る鋼殻を全て先に本溶接し、後から内縁側の棒状鋼材14を挿入する方法もいくつか従来から試みられてきている。   All the steel shells consisting of the skin plate 3, the vertical rib 2, the main girder 1, the joint plate 5, and the outer edge side bar-shaped steel material 15 are first fully welded so that all welding can be performed by the welding robot. Several methods for inserting the rod-shaped steel material 14 have been tried.

内縁側棒状鋼材14が鋼殻内部空間に存在しない状態では、溶接ロボットのトーチ24(図11c参照)が溶接箇所に全て届くことができるというメリットがある。しかし図2に示すように、上記鋼殻内に後から内縁側の棒状鋼材14を挿入しようとすると、継手板5に一番近い縦リブ2の開口部から挿入していくとき、棒状鋼材4と継手板5が干渉して、それ以上先の縦リブ2に棒状鋼材14を通すことが出来ない不具合があった。   In a state where the inner edge side bar-like steel material 14 does not exist in the steel shell inner space, there is an advantage that the torch 24 (see FIG. 11c) of the welding robot can reach all the welding locations. However, as shown in FIG. 2, when the rod-like steel material 14 on the inner edge side is inserted into the steel shell later, when the rod-like steel material 4 is inserted from the opening of the longitudinal rib 2 closest to the joint plate 5. And the joint plate 5 interfere with each other, and there is a problem that the rod-shaped steel material 14 cannot be passed through the longitudinal rib 2 beyond that.

前記の不具合を解決するための一つの方法として、縦リブ2の一部を切り欠く試みが成されているが、縦リブ2の棒状鋼材4の抜け出しに対する耐力が不足してしまう不具合が発生したり、また別の方法として、継手板5に棒状鋼材4挿通用の孔を空けたり継手板5の一部を切り欠いて後から切り欠いた部分を溶接にて取り付ける方法も試みられているが、止水性、防食性状の観点からセグメントとしての性能を損なうことになったり、溶接箇所が増え寸法精度確保が困難になる、ロボット溶接で処理できない場所が増え加工手間が増大するなどの問題は残されたままであった。   As one method for solving the above-mentioned problem, an attempt has been made to cut out a part of the longitudinal rib 2, but there is a problem that the proof strength of the longitudinal rib 2 against the rod-like steel material 4 is insufficient. As another method, a method of making a hole for inserting the bar-like steel material 4 in the joint plate 5 or notching a part of the joint plate 5 and attaching the notched portion later by welding has been tried. However, there are still problems such as loss of performance as a segment from the viewpoint of water-stopping and anti-corrosion properties, increasing the number of welding points, making it difficult to ensure dimensional accuracy, increasing the number of places that cannot be processed by robot welding, and increasing processing effort. Remained.

本発明は前記の問題を解決し、本溶接を溶接ロボットによる作業とすることを可能とし、加工労力を削減し、生産性向上、及びコストダウンが可能な合成セグメントの製造方法を提供することを目的とする。
更には、溶接収縮ひずみ量を削減し、セグメントに必要とされる寸法精度を向上できる合成セグメントの製造方法及び合成セグメントの提供を目的とする。
The present invention provides a method for manufacturing a synthetic segment that solves the above-described problems, enables main welding to be performed by a welding robot, reduces processing labor, improves productivity, and reduces costs. Objective.
Another object of the present invention is to provide a synthetic segment manufacturing method and a synthetic segment that can reduce the amount of welding shrinkage and improve the dimensional accuracy required for the segment.

前記の課題を解決するために、合成セグメントの製造方法を次のように構成する。   In order to solve the above-described problem, the synthetic segment manufacturing method is configured as follows.

第一発明の合成セグメントの製造方法では、主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、縦リブとスキンプレートとを本溶接した後に棒状鋼材を縦リブの開口部に挿通し、その後、鋼殻を一体化して最後に中詰コンクリートを充填する工程を有し、各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする。   In the synthetic segment manufacturing method of the first invention, a main girder, a joint plate, a skin plate, and a steel shell having one or more vertical ribs having an opening, and a rod-shaped steel material at the opening of the vertical rib. In a synthetic segment manufacturing method that is installed crossed and filled with filled concrete, after the main ribs and skin plates are welded together, the bar steel is inserted into the openings of the vertical ribs, and then the steel shell is integrated. And filling with filled concrete at the end, and welding is performed so that the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width To do.

第二発明の合成セグメントの製造方法では、主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、スキンプレートに主桁を仮付け溶接し、開口部を有する縦リブをスキンプレートに本溶接し、棒状鋼材を縦リブの開口部に挿通し、継手板を主桁またはスキンプレートの少なくともいずれかに仮溶接し、その後、スキンプレートと主桁、スキンプレートと継手板、縦リブと主桁、及び主桁と継手板を本溶接して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする。   In the synthetic segment manufacturing method of the second invention, the main girder, the joint plate, the skin plate, and the steel shell having one or more vertical ribs having an opening, and the rod-shaped steel material in the opening of the vertical rib. In a method of manufacturing a composite segment that is installed crossed and filled with filled concrete, the main girder is temporarily welded to the skin plate, the longitudinal ribs with openings are permanently welded to the skin plate, and the bar steel is longitudinally welded. Insert the rib through the opening of the rib and temporarily weld the joint plate to at least one of the main girder or skin plate, then skin plate and main girder, skin plate and joint plate, vertical rib and main girder, and main girder and joint The steel shell is integrated into the steel shell by final welding, and finally the concrete is placed inside the steel shell. The total length of the welded portion of each vertical rib with the skin plate is 5% of the segment width. More than 65% Characterized by welding so as to fully.

第三発明の合成セグメントの製造方法では、主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ仮付け溶接し、主桁のたわみ防止用幅止め材を、残りの継手板の取付位置から残りの継手板に一番近い縦リブの取り付け位置の間に主桁間に渡って設置し、主桁、縦リブ、片側の継手板、及びスキンプレートをそれぞれ本溶接した後、主桁のたわみ防止用幅止め材を外した後に縦リブの開口部に棒状鋼材を挿通する工程、又は縦リブの開口部に棒状鋼材を挿通した後に主桁のたわみ防止用幅止め材を外す工程のいずれか一方の工程の後、残った継手板を本溶接して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする。
In the synthetic segment manufacturing method of the third invention, the main girder, the joint plate, the skin plate, and the steel shell having one or more vertical ribs having an opening, and the rod-shaped steel material in the opening of the vertical rib. In a method of manufacturing a synthetic segment that is installed crossing and filled with filled concrete,
The main girder, vertical rib, one joint plate, and skin plate are tack welded to each other, and the main girder's deflection prevention width stopper is the closest to the remaining joint plate from the remaining joint plate mounting position. The main girder, vertical rib, joint plate on one side, and skin plate are welded to the main girder between the mounting positions of the main girder, and then the width stopper for preventing deflection of the main girder is removed. The remaining joint plate after either step of inserting the rod-shaped steel material into the opening of the rib, or removing the width stopper for preventing deflection of the main girder after inserting the rod-shaped steel material into the opening of the longitudinal rib Has a process of placing concrete inside the steel shell,
It welds so that the sum total of the length of the welding part with the skin plate in each vertical rib may be 5% or more and less than 65% of the segment width.

第四発明の合成セグメントの製造方法では、主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ仮付け溶接し、主桁のたわみ防止用幅止め材を、残りの継手板の取付位置から残りの継手板に一番近い縦リブの取り付け位置の間に主桁間に渡って設置し、主桁、縦リブ、片側の継手板、及びスキンプレートをそれぞれ本溶接した後、縦リブの開口部に棒状鋼材を挿通し、その後、残りの継手板を本溶接してから主桁のたわみ防止用幅止め材を外して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする。
In the synthetic segment manufacturing method of the fourth invention, the main girder, the joint plate, the skin plate, and the steel shell having one or more vertical ribs having an opening, and the rod-shaped steel material in the opening of the vertical rib. In a method of manufacturing a synthetic segment that is installed crossing and filled with filled concrete,
The main girder, vertical rib, one joint plate, and skin plate are tack welded to each other, and the main girder's deflection prevention width stopper is the closest to the remaining joint plate from the remaining joint plate mounting position. After installing the main girder, the vertical rib, the joint plate on one side, and the skin plate between the main girders between the mounting positions of the steel plate, the rod-shaped steel material is inserted into the opening of the vertical rib, and then After the remaining joint plates are fully welded, the main girder deflection prevention width stopper is removed to form an integrated steel shell, and finally the concrete is placed inside the steel shell,
It welds so that the sum total of the length of the welding part with the skin plate in each vertical rib may be 5% or more and less than 65% of the segment width.

第五発明の合成セグメントの製造方法では、主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ仮付け溶接し、トンネル内縁側に凹状開口部を有する縦リブに棒状鋼材を挿通し、凹状の開口部を塞ぐように定着鋼板を縦リブに本溶接し、その後、主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ本溶接して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
前記定着鋼板を縦リブに溶接する前に、定着鋼板の溶接による縦リブの溶接収縮分だけ主桁内縁側間隔を広げて主桁をスキンプレートに仮付け溶接し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする。
In the synthetic segment manufacturing method of the fifth invention, the main girder, the joint plate, the skin plate, and the steel shell having one or more vertical ribs having an opening, and the rod-shaped steel material at the opening of the vertical rib. In a method of manufacturing a synthetic segment that is installed crossing and filled with filled concrete,
The main girder, vertical rib, one joint plate, and skin plate are tack welded to each other, and a steel rod is inserted into the vertical rib having a concave opening on the inner edge of the tunnel, and the fixing steel plate is attached so as to close the concave opening. After the main welding to the vertical rib, the main girder, the vertical rib, one joint plate, and the skin plate are each main welded to form an integrated steel shell, and finally there is a step of placing concrete inside the steel shell. And
Before welding the fixing steel plate to the longitudinal rib, the main girder is temporarily welded to the skin plate by expanding the inner side of the main girder by the welding shrinkage of the longitudinal rib due to welding of the fixing steel plate
It welds so that the sum total of the length of the welding part with the skin plate in each vertical rib may be 5% or more and less than 65% of the segment width.

第六発明の合成セグメントの製造方法では、第一〜第五発明のいずれかの発明において、前記棒状鋼材を前記合成セグメント用の鋼殻内に挿入する際、合成セグメント用の鋼殻を組み立て治具と共に角度調整可能なポジショナーの上に載置して固定し、ポジショナーを所定の角度に調整した後に、棒状鋼材を合成セグメント用の鋼殻内に挿入することを特徴とする。   In the synthetic segment manufacturing method of the sixth invention, in the invention of any one of the first to fifth inventions, when the rod-shaped steel material is inserted into the synthetic segment steel shell, the synthetic segment steel shell is assembled and cured. It mounts on the positioner which can be angle-adjusted with a tool, is fixed, and after adjusting a positioner to a predetermined angle, rod-shaped steel materials are inserted in the steel shell for synthetic segments.

第七発明の合成セグメントでは、主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントであって、各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満であることを特徴とする。   In the synthetic segment of the seventh invention, a steel beam having one or more longitudinal ribs having a main girder, a joint plate, a skin plate, and an opening, and a rod-shaped steel material intersecting the opening of the longitudinal rib. A synthetic segment that is installed and filled with filled concrete, wherein the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.

本発明において、仮付け溶接は、部材を組立ててセグメントを形作るときに仮固定するための点付け溶接(例えば、全溶接長さ20mm程度)と定義し、前記点付け溶接とは接合強度上異なる本溶接は設計図面に記載されている仕様の溶接と定義する。   In the present invention, tack welding is defined as spot welding (for example, a total weld length of about 20 mm) for temporarily fixing when assembling members to form a segment, and is different from the spot welding in terms of joint strength. Welding is defined as welding with the specifications described in the design drawings.

本発明により、棒状鋼材と縦リブが複雑に密実に配設されて、溶接ロボットによる本溶接ができないような箇所に対して、本溶接を溶接ロボットによる作業とすることが可能となり加工労力が大幅に削減され、合成セグメントの生産性向上・コストダウンをもたらすことができる。
更には、スキンプレートと縦リブ間の溶接量を減らことができ、溶接の時間とコストを削減できることに加えて、溶接収縮ひずみ量を削減できるため、セグメントに必要とされる寸法精度も向上する。
According to the present invention, it is possible to make the main welding work by the welding robot in a place where the rod-shaped steel material and the vertical rib are arranged densely and densely and the main welding cannot be performed by the welding robot, and the processing labor is greatly increased. Can reduce the productivity of synthetic segments and reduce costs.
Furthermore, the amount of welding between the skin plate and the longitudinal rib can be reduced, and in addition to reducing the welding time and cost, the amount of welding shrinkage can be reduced, so that the dimensional accuracy required for the segment is also improved. .

以下、本発明の合成セグメントの製造方法について説明する。   Hereinafter, the manufacturing method of the synthetic segment of this invention is demonstrated.

本発明においては、図3の製作手順フローに示すように、縦リブとスキンプレートを本溶接し、棒状鋼材を縦リブに交差するように挿通した後に、鋼殻の本溶接を行うため、従来の製造方法では困難であった、本溶接のロボット溶接化が可能になり、製作時間、コストを削減できる効率の良い合成セグメントの製造を行うことができる。   In the present invention, as shown in the production procedure flow of FIG. 3, the main welding of the steel shell is performed after the longitudinal rib and the skin plate are finally welded and the rod-shaped steel material is inserted so as to intersect the longitudinal rib. This manufacturing method makes it possible to perform robot welding of the main welding, which is difficult with this manufacturing method, and it is possible to manufacture an efficient synthetic segment that can reduce manufacturing time and cost.

第一発明の実施形態を以下に示す。
図11に製造手順の図を示すように、スキンプレート3を船型治具12(図12参照)上に載せ(図11a参照)、主桁1をスキンプレート3の上にシャコ万23等で船型治具12に仮固定しセットする(図11b参照)。主桁1とスキンプレート3は仮溶接しておく。次に縦リブ2を主桁1間に挟みスキンプレート3に本溶接してしまい(図11c、d参照)、その後縦リブ2内に棒状鋼材4を挿入する(図11d参照)。棒状鋼材4挿入後、継手板5を治具内にセットし仮溶接し(図11e参照)、全鋼殻を治具から搬出後、主桁1と継手板5の本溶接をし、主桁1と縦リブ2の本溶接をし、スキンプレート3周縁部を主桁1と継手板5に本溶接する。
Embodiments of the first invention are shown below.
As shown in FIG. 11, the skin plate 3 is placed on the boat-shaped jig 12 (see FIG. 12) (see FIG. 11 a), and the main girder 1 is placed on the skin plate 3 with a scale 23, etc. Temporarily fix and set the jig 12 (see FIG. 11b). The main beam 1 and the skin plate 3 are temporarily welded. Next, the longitudinal ribs 2 are sandwiched between the main girders 1 and finally welded to the skin plate 3 (see FIGS. 11c and 11d), and then the bar-shaped steel material 4 is inserted into the longitudinal ribs 2 (see FIG. 11d). After inserting the rod-shaped steel material 4, the joint plate 5 is set in a jig and temporarily welded (see FIG. 11 e). After the entire steel shell is taken out of the jig, the main girder 1 and the joint plate 5 are finally welded, 1 and the longitudinal rib 2 are finally welded, and the periphery of the skin plate 3 is finally welded to the main girder 1 and the joint plate 5.

一般的に合成セグメントと構造上異なる鋼製セグメントでは、シールドマシンのジャッキ推力を縦リブ2で受けているため縦リブ2の取り付け位置精度(通り)が重要になる。取り付け位置精度が悪いとジャッキ推力を受けたとき主桁1や縦リブ2、スキンプレート3の座屈の原因となる。事前にスキンプレート3に縦リブ2を取り付ける方法では、スキンプレート3の切断精度、曲げ精度や縦リブ2の取り付け位置、角度の影響があり鋼製セグメントに要求される縦リブ2の位置精度を確保できない。   In general, a steel segment that is structurally different from a synthetic segment receives the jacking force of the shield machine by the vertical rib 2, so that the accuracy of the installation position (street) of the vertical rib 2 becomes important. If the mounting position accuracy is poor, it will cause buckling of the main girder 1, vertical rib 2 and skin plate 3 when jacking force is applied. In the method of attaching the vertical rib 2 to the skin plate 3 in advance, the accuracy of the vertical rib 2 required for the steel segment is affected by the cutting accuracy of the skin plate 3, the bending accuracy, the mounting position of the vertical rib 2 and the angle. It cannot be secured.

しかし合成セグメントでは、ジャッキ推力は中詰めされたコンクリート6が受け持つため、縦リブ2の取り付け位置精度はラフでよく、スキンプレート3に縦リブ2を最初に本溶接にて取り付けてしまうことに対して何ら支障は生じない。   However, in the synthetic segment, the concrete thrust 6 is responsible for the jack thrust, so the accuracy of the mounting position of the vertical rib 2 may be rough, and the vertical rib 2 is first attached to the skin plate 3 by the main welding first. Will not cause any trouble.

第一,第二および第六発明の一実施形態の詳細の組み立て手順を以下の(1)〜(6)に示す。
(1)組み立て治具内にスキンプレート3、主桁1の部材を配置し、主桁1は治具にシャコ万23等で固定し、スキンプレート3と主桁1は仮付け溶接を行う。組み立て治具としては、下向きで作業ができるように、曲率を有する船型の治具とすることで作業効率が向上する。
Detailed assembly procedures of one embodiment of the first, second and sixth inventions are shown in the following (1) to (6).
(1) The members of the skin plate 3 and the main girder 1 are arranged in the assembly jig, the main girder 1 is fixed to the jig with a scale 2323, etc., and the skin plate 3 and the main girder 1 are tack welded. As the assembly jig, work efficiency is improved by using a ship-shaped jig having a curvature so that the work can be performed downward.

船型治具12の構造としては、図12に示すように、間隔をおいて平行に同レベルに配置された主桁仮固定用板材26の間に複数枚のスキンプレート設置用桁材25を間隔をおいて平行に、かつ上面が前記板材26の上面よりも低レベル位置になるように配置し、これらを一体に結合するようにこれらに渡って配置された鋼製繋ぎ材27により一体化された構造であり、形成する合成セグメントの鋼殻と同じ曲率のついた前記桁材25を下端に敷き、その桁材25の円弧内縁側(上面側)の上にスキンプレート3を設置できるようにする。スキンプレート3がたわまず安定して受けることができるよう、船型治具12の中の桁材25は2列以上配置することが好ましい。円弧方向両サイドに主桁1を仮置するための板材26を上述のスキンプレート設置用桁材25に平行に取り付ける。   As shown in FIG. 12, the structure of the hull-shaped jig 12 is such that a plurality of skin plate setting girders 25 are spaced between main girder temporary fixing plate members 26 arranged at the same level in parallel at intervals. Are arranged in parallel with each other so that the upper surface is located at a lower level than the upper surface of the plate member 26, and are integrated by a steel connecting member 27 disposed over them so as to be integrally connected to each other. The girder 25 having the same curvature as the steel shell of the synthetic segment to be formed is laid on the lower end, and the skin plate 3 can be installed on the arc inner edge side (upper surface side) of the girder 25 To do. It is preferable to arrange two or more rows of girders 25 in the boat-shaped jig 12 so that the skin plate 3 can be received stably without bending. A plate member 26 for temporarily placing the main girder 1 on both sides in the arc direction is attached in parallel to the above-described girder member 25 for installing the skin plate.

セグメントの最終形状が寸法許容誤差内に精度良くできるよう、主桁仮固定用板材26の間隔はセグメント鋼殻の両側の主桁1を覆うように所定のセグメント幅間隔(両サイドの主桁1外面距離)になるよう設置することが好ましい。主桁仮固定用板材26には作業効率を上げるため予め縦リブ2を配置する位置をマークしておき、縦リブ2を鋼殻内に設置する際は、製作精度を確保して主桁1に垂直に固定できるよう、両側の主桁仮固定用板材26に垂直に跨ぐ補助治具28を作成しておき、その補助治具28を両側の主桁仮固定用板材26に垂直に跨ぐように適宜の着脱可能な固定金具(図示を省略)を使用して設置し、この補助治具28に沿わせて縦リブ2をスキンプレート3上に配置しスキンプレート3と縦リブ2を溶接する。主桁1に垂直に設置された縦リブ設定用補助治具28を利用することで、縦リブ2は主桁1に垂直に取り付けることができる。   The distance between the main girder temporary fixing plate members 26 is a predetermined segment width interval (the main girder 1 on both sides) so as to cover the main girder 1 on both sides of the segment steel shell so that the final shape of the segment can be accurately performed within the dimensional tolerance. (External surface distance). The main girder temporary fixing plate 26 is preliminarily marked with the position where the vertical rib 2 is arranged in order to increase the work efficiency, and when the vertical rib 2 is installed in the steel shell, the manufacturing accuracy is ensured and the main girder 1 is secured. An auxiliary jig 28 is formed so as to straddle the main girder temporary fixing plate members 26 on both sides so that the auxiliary jig 28 can be vertically fixed to the main girder temporary fixing plate members 26 on both sides. Is installed using an appropriate detachable fixing bracket (not shown), the vertical rib 2 is arranged on the skin plate 3 along the auxiliary jig 28, and the skin plate 3 and the vertical rib 2 are welded. . The vertical rib 2 can be attached to the main girder 1 vertically by using the auxiliary jig 28 for setting the vertical rib installed perpendicularly to the main girder 1.

(2)縦リブ2とスキンプレート3との本溶接を仮組治具内で行う。
本溶接の方法としては、図6に示すように、縦リブ2の両側に縦リブ2の長手方向に位置をずらすような千鳥断続溶接にし縦リブ2の両側およびセグメント幅方向に均等にバランスよく溶接箇所を配置することが構造の安定上好ましいが、縦リブ2の両側で溶接位置が同じになる並列断続溶接にしてもいいし、縦リブ2の片面のみの溶接にしても構わない。縦リブ2とスキンプレート3の接触箇所全長に渡って溶接しても構わないが、溶接後に生じるひずみの影響が大きくなり製作精度が悪くなり易かったり、加工コストが嵩んだりするため、全長溶接は避ける方が好ましい。
(2) The main welding of the vertical rib 2 and the skin plate 3 is performed in a temporary assembly jig.
As shown in FIG. 6, the main welding method is staggered intermittent welding in which the longitudinal ribs 2 are shifted in the longitudinal direction on both sides of the longitudinal ribs 2, with a good balance evenly on both sides of the longitudinal ribs 2 and the segment width direction. Although it is preferable for the stability of the structure to arrange the welding location, it may be a parallel intermittent welding in which the welding positions are the same on both sides of the vertical rib 2 or may be a welding of only one side of the vertical rib 2. Welding may be performed over the entire length of the contact area between the vertical rib 2 and the skin plate 3, but since the influence of strain generated after welding becomes large, the manufacturing accuracy tends to deteriorate, and the processing cost increases. Is preferred to avoid.

組み立て船型治具内12で全ての部材の本溶接を行うと、溶接時間分、前記治具12の専有時間が長くなり生産効率が悪化する。生産量を確保するには、治具12の台数が増えコスト高となるため、仮組用の前記治具12内では鋼殻の仮付けまでを行い、本溶接は治具12から取り出して行う。合成セグメントにおいては、ジャッキ推力をコンクリート6で受け縦リブ2はジャッキ推力を受けずスキンプレート3への固定度が低くても構わないため、縦リブ2におけるスキンプレート3との溶接の脚長、合計溶接長が少なくてよく、仮組時に治具12内でこの部分の本溶接をしても、治具12の専有時間は短い。治具12の台数を増やさずにすみコストへの影響が小さい。   If the main welding of all the members is performed in the assembled boat-shaped jig 12, the exclusive time of the jig 12 is increased by the welding time, and the production efficiency is deteriorated. In order to secure the production amount, the number of jigs 12 is increased and the cost is increased, so that the steel shell is temporarily attached in the jig 12 for temporary assembly, and the main welding is performed by taking out from the jig 12. . In the composite segment, the jack thrust is received by the concrete 6 and the vertical rib 2 does not receive the jack thrust and the degree of fixation to the skin plate 3 may be low. The welding length may be small, and even if this part is fully welded in the jig 12 during temporary assembly, the time required for the jig 12 is short. The effect on cost is small without increasing the number of jigs 12.

作業効率を上げるためには、スキンプレート3と縦リブ2の溶接はロボットにて実施することが好ましい。溶接ロボットは、アームの付いた形状をしており、そのアームの先端に図11に示すトーチ24が固定されている。
(3)組み立て船型治具12内で内外周の棒状鋼材4(14,15)を挿入する。
(4)組み立て船型治具12内で棒状鋼材4(14,15)を挿入するとき、治具12を図8に示すポジショナー11に取り付け、挿入しやすいよう前記治具12の姿勢を変化させてもよい。
In order to increase the working efficiency, it is preferable to perform welding of the skin plate 3 and the vertical rib 2 by a robot. The welding robot has a shape with an arm, and a torch 24 shown in FIG. 11 is fixed to the tip of the arm.
(3) The rod-shaped steel materials 4 (14, 15) on the inner and outer circumferences are inserted into the assembled boat-shaped jig 12.
(4) When the rod-shaped steel material 4 (14, 15) is inserted into the assembled boat-shaped jig 12, the jig 12 is attached to the positioner 11 shown in FIG. 8, and the posture of the jig 12 is changed so that it can be easily inserted. Also good.

ポジショナー11は、水平面上に設置する基板31に垂直に支柱32が取り付けられ、前記支柱32に回転盤33が回転可能に取り付けられ、前記回転盤33に基端部が取付けられた支持アームを介して受け台29を支えている。回転盤33を回転させることで受け台29を任意の角度に設定できる。船型治具12は受け台29に図示省略のボルト・ナット等の着脱可能な固定手段により固定され、船型治具12を受け台29に載荷するためその受け台29の曲率は船型治具12と同等にすることが望ましい。また所定の位置に受け台29を回転させる方法としては、モーター等の駆動装置よる方式でも手動方式でもよい。例えば、回転盤33を支柱32に回転可能に支持すると共に、支柱32側に駆動装置または手動式ハンドルを取付け、回転盤32内に固定の内歯歯車を駆動ピニオンに噛み合わせて、回転盤32を回転させるようにしてもよい。   The positioner 11 is provided with a support 32 having a support 32 in which a support 32 is vertically attached to a substrate 31 installed on a horizontal plane, a turntable 33 is rotatably attached to the support 32, and a base end is attached to the turntable 33. The cradle 29 is supported. The cradle 29 can be set at an arbitrary angle by rotating the turntable 33. The hull jig 12 is fixed to the cradle 29 by means of detachable fixing means such as bolts and nuts (not shown). Since the hull jig 12 is loaded on the cradle 29, the curvature of the cradle 29 is the same as that of the hull jig 12. It is desirable to make them equal. Further, as a method of rotating the cradle 29 at a predetermined position, a method using a driving device such as a motor or a manual method may be used. For example, the turntable 33 is rotatably supported by the support 32, a drive device or a manual handle is attached to the support 32, and a fixed internal gear is meshed with the drive pinion in the turntable 32. You may make it rotate.

(5)治具12内で継手板5を組み立て、仮付け溶接を行う。
(6)組み立て治具12から仮組されたセグメントを取り出し、本溶接を行う。
仮組用の治具12の構造により溶接のやりにくい箇所や、舟型治具12でのスキンプレート3外周溶接のように溶接できない箇所があるためセグメントを治具12から出さないと全てを本溶接することができない。また、仮組用の治具12内で全て本溶接を行ってしまうと溶接収縮によりセグメントが変形し、治具12から取り出せなくなる可能性があるため、治具12内で全ての本溶接をしてしまうことは避ける方が好ましい。
(5) The joint plate 5 is assembled in the jig 12, and tack welding is performed.
(6) The temporarily assembled segment is taken out from the assembly jig 12 and main welding is performed.
Because there are places where welding is difficult due to the structure of the jig 12 for temporary assembly, and there are places where welding is not possible, such as the outer periphery welding of the skin plate 3 with the boat-type jig 12, all of the segments must be taken out of the jig 12 It cannot be welded. In addition, if all the main welding is performed in the temporary assembly jig 12, the segments may be deformed due to welding shrinkage and cannot be removed from the jig 12. It is better to avoid that.

実物大の鋼殻組み立て試験を実施したところ、全て溶接ロボットにて溶接が可能となり鋼殻の製作時間が従来の鋼製セグメントと同程度で達成できることを確認した。またポジショナー11の角度としては、スキンプレート3、主桁1、縦リブ2を仮溶接し、継手板5を組み込みスキンプレート3と本溶接するときは下向き溶接となるよう、船型の治具12は曲率のついている内縁側が上向きとなるように設置し、棒状鋼材4挿入時はセグメント長手方向を軸にして90度横に傾ける(図8c参照)ことで作業負荷を低減できることを確認した。   When a full-scale steel shell assembly test was conducted, it was confirmed that all welding was possible with a welding robot, and that the production time of the steel shell could be achieved to the same extent as the conventional steel segment. The angle of the positioner 11 is such that the skin plate 3, the main girder 1, and the longitudinal rib 2 are temporarily welded, and when the joint plate 5 is incorporated and the main plate is welded to the skin plate 3, the ship-shaped jig 12 is welded downward. It was confirmed that the work load could be reduced by inclining sideways by 90 degrees about the longitudinal direction of the segment (see FIG. 8c) when the rod-shaped steel material 4 was inserted, with the inner edge side with curvature facing upward.

一般に、鋼製セグメントにおいては縦リブ2とスキンプレート3を一体化させるために、図7(a)(b)に示すように、縦リブ2一本当りの縦リブ2両サイドの溶接10の合計溶接長をセグメント幅の65%以上確保するよう、トンネル標準示方書(土木学会)、シールド工事用標準セグメント(日本下水道協会)に図示されている。   Generally, in order to integrate the vertical rib 2 and the skin plate 3 in the steel segment, as shown in FIGS. 7 (a) and 7 (b), as shown in FIGS. In order to secure a total weld length of 65% or more of the segment width, it is shown in the tunnel standard specification (Japan Society of Civil Engineers) and the shield standard segment (Japan Sewerage Association).

対して、合成セグメントにおける縦リブ2の機能は、a)棒状鋼材4のセグメント内部からの抜け出しを防ぐこと、b)トンネル半径方向のせん断力に対して引張り材として抵抗することだけであり、スキンプレート3と強固に一体化する必要がなく、縦リブ2−スキンプレート3間の縦リブ2一本当りの溶接長は、一般的な鋼製セグメントと比べて少なくても部材として成り立つことが判り、セグメント幅の65%未満でよいことを見出した。   On the other hand, the functions of the longitudinal ribs 2 in the composite segment are only a) to prevent the rod-shaped steel material 4 from coming out from the inside of the segment, and b) to resist the shearing force in the tunnel radial direction as a tensile material. It is not necessary to be firmly integrated with the plate 3, and the welding length per vertical rib 2 between the vertical rib 2 and the skin plate 3 can be realized as a member at least as compared with a general steel segment. And found that it may be less than 65% of the segment width.

全くスキンプレート3に縦リブ2を溶接しないと、コンクリート6打設時にスキンプレート3が不均一に面外方向へはらみ出したり、セグメントを運搬する際スキンプレート3がたわみ作業性が低下したりする恐れがあるので、少なくとも縦リブ2とスキンプレート3の溶接長さとして、仮付け溶接程度の溶接量となるセグメント幅に対して5%以上を確保することが必要である。   If the vertical ribs 2 are not welded to the skin plate 3 at all, the skin plate 3 may protrude unevenly when the concrete 6 is placed, or the skin plate 3 may bend when the segments are transported, and workability of the skin plate 3 may be reduced. Since there is a fear, it is necessary to secure 5% or more with respect to the segment width which is a welding amount of about the tack welding as the welding length of at least the vertical rib 2 and the skin plate 3.

セグメントを2次設計し高い変形性能を確保するためには、スキンプレート3と縦リブ2の一体性を高め中詰めコンクリート6の拘束効果を増すことを目的として、縦リブ2とスキンプレート3の溶接長さのセグメント幅に対する割合として10%以上確保すればよい。経済性も考慮すると10〜30%程度にすることが好ましい。更に、経済性に加えて作業性及び溶接によるひずみ防止の観点も加えると、10〜20%にすることが最も好ましい。前記のように仮組されたセグメントを本溶接した後、図1に示すように棒状鋼材4を埋め込むように中詰めコンクリート6を充填して合成セグメント13が製造される。したがって、合成セグメントの製造手順および縦リブ2におけるスキンプレート3との溶接部長さが従来の場合と異なる以外は、従来と同様図1に示すような合成セグメント13が製造される。   In order to ensure the high deformation performance by secondary design of the segment, the vertical rib 2 and the skin plate 3 are formed for the purpose of increasing the integrity of the skin plate 3 and the vertical rib 2 and increasing the restraining effect of the filling concrete 6. What is necessary is just to ensure 10% or more as a ratio with respect to the segment width of welding length. Considering economic efficiency, it is preferable to make it about 10 to 30%. Furthermore, in addition to economical efficiency, when considering the workability and the viewpoint of distortion prevention by welding, it is most preferable that the content be 10 to 20%. After the segments temporarily assembled as described above are main-welded, as shown in FIG. 1, the filled concrete 6 is filled so as to embed the rod-shaped steel material 4, thereby producing the synthetic segment 13. Therefore, the synthetic segment 13 as shown in FIG. 1 is produced in the same manner as in the prior art except that the synthetic segment manufacturing procedure and the welded portion length of the vertical rib 2 with the skin plate 3 are different from the conventional case.

次に、図4,5に示すような幅止め材8,9を用いて片方の継手板5を後付けにする方式の第三及び第四発明に関する一実施形態を以下に示す。なお、幅止め材8,9を使用する点および組み立て最後に継手板の取付以外は、前記実施形態と同様であるので、同様な部分は前記の説明を援用し、相違する部分を主に説明する。
図4に示すような、幅止め材8を主桁1間に挟む場合について示す。
(1)組み立て治具内に主桁1、縦リブ2、片方の継手板5、スキンプレート3部材を配置し仮付け溶接を行う。
(2)反対側の開口した継手部はセグメント幅寸法を確保するため簡易な幅止め材8を設置する。取り付けは、仮付け溶接してもいいし、シャコ万等で機械的に固定してもよい。
(3)組み立て治具から仮組されたセグメントを取り出し、第一の本溶接を行う。
(4)本溶接終了後棒状鋼材4を挿入する。幅止め材8としては、棒状鋼材4が挿入できるよう予め棒状鋼材4挿通用の開口を設けて置くことが好ましいが、板材を幅止め材8として使用するときは、棒状鋼材4挿通前に幅止め材8を外し、その後棒状鋼材4を縦リブ2内に挿通する。
(5)残りの継手板を取り付け、第二の本溶接を行う。
Next, an embodiment related to the third and fourth inventions of a system in which one of the joint plates 5 is retrofitted using the width stoppers 8 and 9 as shown in FIGS. In addition, since it is the same as that of the said embodiment except the point which uses the width | variety stoppers 8 and 9, and attachment of a joint plate at the end of an assembly, the same part uses the said description and mainly demonstrates a different part. To do.
The case where the width stop material 8 as shown in FIG.
(1) The main girder 1, the longitudinal rib 2, the joint plate 5 on one side, and the skin plate 3 member are placed in an assembly jig and tack welding is performed.
(2) A simple width stop member 8 is installed in the joint portion opened on the opposite side in order to secure the segment width dimension. The attachment may be tack welding, or may be mechanically fixed with a scale.
(3) Take out the temporarily assembled segment from the assembly jig and perform the first main welding.
(4) After the main welding is finished, the rod-shaped steel material 4 is inserted. As the width stop material 8, it is preferable to provide an opening for inserting the rod-shaped steel material 4 in advance so that the rod-shaped steel material 4 can be inserted. However, when the plate material is used as the width stop material 8, the width before the rod-shaped steel material 4 is inserted. The stop material 8 is removed, and then the rod-shaped steel material 4 is inserted into the vertical rib 2.
(5) Install the remaining joint plates and perform the second main welding.

第一の本溶接を行うときはセグメントの内面には棒状鋼材4がないため、溶接の作業性が良い。幅止め材8としては、主桁1の内縁側から外縁側にかけて一様に主桁1のたわみを防ぐ目的から、継手板5と同程度の高さの鋼板を用いるのが好ましい。   When the first main welding is performed, there is no bar-like steel material 4 on the inner surface of the segment, so that the workability of welding is good. As the width stopper 8, it is preferable to use a steel plate having a height similar to that of the joint plate 5 in order to prevent the deflection of the main girder 1 uniformly from the inner edge side to the outer edge side of the main girder 1.

また幅止め材8としては、上記のように主桁1間に挟むのではなく、図5に示すような幅止め材9のように、両方の主桁1の外側から取り付けてもよい。この場合、幅止め材9を主桁1間に挟む場合の工程の前記(4)において、棒状鋼材4を挿入するとき幅止め材9を外さず残しておき、前記(5)の工程で幅止め材9を使用したまま残りの継手板5を溶接すれば、幅止め材9を外した際に生じる主桁1の自由端部の変形を防止することができる。   Further, the width stopper 8 may be attached from the outside of both the main girders 1 as shown in FIG. 5 instead of being sandwiched between the main girders 1 as described above. In this case, in the step (4) in the case where the width stopper material 9 is sandwiched between the main girders 1, when the rod-shaped steel material 4 is inserted, the width stopper material 9 is left without being removed, and the width in the step (5). If the remaining joint plate 5 is welded while the stopper 9 is used, the deformation of the free end portion of the main girder 1 that occurs when the width stopper 9 is removed can be prevented.

次に、第五発明に係る実施形態を、図9,図10,図13および図14を参照しながら以下の(1)〜(4)に示す。なお、定着鋼板16を縦リブに溶接したときに発生する縦リブの溶接縮み代を考慮する以外は、前記実施形態と同様であるので、同様な部分は前記の説明を援用し、相違する部分を主に説明する。
(1)主桁1,スキンプレート3,縦リブ2を船型治具内12で仮組みし、主桁1と縦リブ2,スキンプレート3と主桁1・縦リブ2の仮付け溶接を行う。定着鋼板16を縦リブに溶接したときに発生する縦リブの溶接縮み代を考慮し、図10に示すように、主桁1の内周側をh18だけ幅を広げて仮組みする。縦リブ2に定着鋼板16を溶接した後の最終状態において、セグメントの幅がシールド工事用標準セグメント(日本下水道協会)の鋼製セグメントに規定されている±1.5mm以内となるよう、予め溶接縮み代を実際に検証し、主桁1の内周側の広げ幅h18の許容誤差を確認しておくことが望ましい。
Next, an embodiment according to the fifth invention is shown in the following (1) to (4) with reference to FIG. 9, FIG. 10, FIG. 13 and FIG. In addition, since it is the same as that of the said embodiment except considering the welding shrinkage allowance of the vertical rib which generate | occur | produces when the fixing steel plate 16 is welded to the vertical rib, the same part uses the said description and is a different part. Is mainly explained.
(1) The main girder 1, skin plate 3 and vertical rib 2 are temporarily assembled in the boat-shaped jig 12 and the main girder 1 and vertical rib 2 and skin plate 3 and main girder 1 and vertical rib 2 are tack welded. . Considering the welding shrinkage allowance of the vertical ribs generated when the fixing steel plate 16 is welded to the vertical ribs, as shown in FIG. In the final state after welding the fixing steel plate 16 to the vertical rib 2, the width of the segment is welded in advance so that it is within ± 1.5 mm as defined in the steel segment of the standard segment for shield construction (Japan Sewerage Association). It is desirable to actually verify the shrinkage allowance and confirm the allowable error of the expansion width h18 on the inner peripheral side of the main beam 1.

(2)外周側棒状鋼材15を挿入する。
(3)船型治具内12で継手板5を設定(所定の位置に配置して仮付け溶接)し、船型治具12内からセグメント本体を取り出し、セグメント本体(主桁1と縦リブ2の本溶接,主桁1と継手板5の本溶接,スキンプレート3と主桁1・継手板5・縦リブ2の本溶接)の本溶接を行う。
(2) Insert the outer peripheral side bar-shaped steel material 15.
(3) The joint plate 5 is set in the ship-shaped jig 12 (positioned at a predetermined position and tack welded), the segment main body is taken out from the ship-shaped jig 12, and the segment main body (the main girder 1 and the vertical rib 2 Main welding, main welding of the main girder 1 and the joint plate 5, and main welding of the skin plate 3 and the main girder 1, the joint plate 5, and the vertical rib 2) are performed.

(4)縦リブ2の内周側の凹状開口部7aに棒状鋼材14を嵌め込んだ後、図9(b)または図13(a)〜(c)に示すように、定着鋼板16をかぶせ溶接にて取り付ける。定着鋼板16と縦リブ2の本溶接を行うと、溶接収縮により内周側の主桁1間隔が縮まり、内外周とも所定のセグメント幅寸法を満足する設計寸法となる。外周側は先にスキンプレート3溶接をして拘束されているため、内周側に定着鋼板16を溶接しても幅寸法の変動は無い。 (4) After the rod-shaped steel material 14 is fitted into the concave opening 7a on the inner peripheral side of the vertical rib 2, as shown in FIG. 9 (b) or FIGS. 13 (a) to (c), the fixing steel plate 16 is covered. Install by welding. When the welding of the fixing steel plate 16 and the longitudinal rib 2 is performed, the interval between the main girder 1 on the inner peripheral side is reduced due to welding contraction, and the inner and outer peripherals are designed to satisfy a predetermined segment width dimension. Since the outer peripheral side is restrained by the skin plate 3 welding first, even if the fixing steel plate 16 is welded to the inner peripheral side, the width dimension does not change.

定着鋼板16の縦リブ2への取り付け方法としては、図13(a)〜(c)に示すように、棒状鋼材14を縦リブ2の側面に取り付けることが、加工のし易さから好ましいが、図14に示すように、縦リブ2の端部に載せて溶接により固定しても構わない。   As a method of attaching the fixing steel plate 16 to the longitudinal rib 2, it is preferable from the viewpoint of ease of processing that the rod-shaped steel material 14 is attached to the side surface of the longitudinal rib 2 as shown in FIGS. As shown in FIG. 14, it may be mounted on the end of the vertical rib 2 and fixed by welding.

実物大(セグメント幅1200mm,桁高250mm)の試験体を用いて、合成セグメントの縦リブ2−スキンプレート3間の縦リブ2一本当りの溶接長をセグメント幅の15%としたところ、溶接時間・溶接によるひずみの補正時間が,従来の場合と比べて1/5程度縮減され、鋼殻製作総時間が従来の65%以上溶接していたときに比べ半減した。また、溶接長が減ったことにより鋼殻の幅寸法の精度が向上し、シールド工事用標準セグメント(日本下水道協会)に規定されている寸法の許容差を逸脱することが一切無くなり、スキンプレート3−縦リブ2の溶接後のひずみ補正を全く必要としなくなった。また溶接長が減ったことによる構造強度性能への影響を調べるため、上記の試験体を用いて、単体曲げ試験、ジャッキ推力試験を行ったが、いずれの試験においても試験体は設計荷重を上回る耐力を示し、また設計荷重までスキンプレート3が面外へはらみ出し座屈することも無く、溶接長削減の影響が構造強度的に全くないことを確認した。   Using a test piece of actual size (segment width 1200mm, girder height 250mm), the welding length per vertical rib 2 between the vertical rib 2 and the skin plate 3 of the composite segment is 15% of the segment width. The time and the distortion correction time due to welding were reduced by about 1/5 compared to the conventional case, and the total manufacturing time of the steel shell was halved compared to when the conventional welding time was 65% or more. In addition, the reduction in weld length improves the accuracy of the width of the steel shell, and there is no deviation from the dimensional tolerance specified in the standard segment for shield construction (Japan Sewerage Association). -Strain correction after welding of the vertical ribs 2 is no longer necessary. In addition, in order to investigate the influence on the structural strength performance due to the decrease in weld length, a single bending test and a jack thrust test were performed using the above-mentioned test specimens, but the test specimens exceeded the design load in both tests. It showed proof strength, and the skin plate 3 did not protrude out of the plane and buckled up to the design load, and it was confirmed that there was no influence on the weld strength reduction in terms of structural strength.

第五発明による定着鋼板16を用いる構造のセグメント製造方法に関して、実物大(セグメント幅1200mm,桁高250mm)の試験体を用いて、鋼板溶接前に主桁内縁側21に予め設ける縮み代の実験を実施した。その結果、縦リブ2に取り付ける鋼板を、図13(b)に示すように、開先6mm+隅肉4mmで溶接する場合は4.2mm、図13(c)に示すように、隅肉4mmのみで溶接する場合は3.1mmのセグメント幅方向主桁内縁側21位置で溶接収縮が発生することが分かり、その分、予め主桁1間隔を広げてセグメント幅を広くして加工した場合、定着鋼板16を縦リブ2に溶接した後のセグメントの幅寸法が所定の精度内に収まることを確認した。   Regarding the segment manufacturing method of the structure using the fixed steel plate 16 according to the fifth invention, a shrinkage allowance experiment previously provided on the inner side 21 of the main girder before welding the steel plate using a full-size test piece (segment width 1200 mm, girder height 250 mm) Carried out. As a result, as shown in FIG. 13 (b), the steel plate to be attached to the vertical rib 2 is 4.2mm when welding with a groove 6mm + fillet 4mm, and only with a fillet 4mm as shown in FIG. 13 (c). In the case of welding, it can be seen that welding shrinkage occurs at the position 21 in the inner edge side of the 3.1 mm segment width direction main girder. It was confirmed that the width dimension of the segment after welding to the vertical rib 2 was within a predetermined accuracy.

合成セグメントの構造を示す一部を省略した斜視図である。It is the perspective view which abbreviate | omitted a part which shows the structure of a synthetic | combination segment. 棒状鋼材と継手板が干渉し、棒状鋼材を挿入できない例を示した図である。It is the figure which showed the example which bar-shaped steel materials and a joint board interfere and cannot insert bar-shaped steel materials. 本発明に係る合成セグメントの製作手順フローチャートを示した図である。It is the figure which showed the manufacture procedure flowchart of the synthetic segment which concerns on this invention. 本発明に係る幅止め材を用いた例を示した図である。It is the figure which showed the example using the width stop material which concerns on this invention. 本発明に係る主桁の外側から覆う形状の幅止め材を用いた例を示した図である。It is the figure which showed the example using the width | variety stopper material of the shape covered from the outer side of the main beam which concerns on this invention. 本発明に係る合成セグメントの縦リブとスキンプレートの本溶接の一例を示した図である。It is the figure which showed an example of the main welding of the vertical rib of the synthetic | combination segment which concerns on this invention, and a skin plate. 従来の鋼製セグメントの縦リブとスキンプレートの本溶接の一例を示した図である。It is the figure which showed an example of the main welding of the longitudinal rib and skin plate of the conventional steel segment. (a)〜(c)は本発明に係るポジショナーの利用方法を示した図である。(A)-(c) is the figure which showed the utilization method of the positioner based on this invention. 本発明に係る穴あけ加工のみの縦リブ(a)と定着鋼板を取り付ける縦リブ(b)の一例を示した図である。It is the figure which showed an example of the vertical rib (b) which attaches the vertical rib (a) only for drilling which concerns on this invention, and a fixing steel plate. 本発明に係る定着鋼板を用いた場合の主桁の嵩上げを示した図である。It is the figure which showed the raising of the main girder at the time of using the fixing steel plate which concerns on this invention. (a)〜(e)は本発明に係る合成セグメントの製造方法の一例を示した図である。(A)-(e) is the figure which showed an example of the manufacturing method of the synthetic segment which concerns on this invention. 本発明に係る船型治具を示した図である。It is the figure which showed the hull form jig | tool which concerns on this invention. 本発明に係る定着鋼板を縦リブに取り付けた例(縦リブの側面に定着鋼板を取り付けた場合)を示した図である。It is the figure which showed the example (when a fixing steel plate is attached to the side surface of a vertical rib) which attached the fixing steel plate which concerns on this invention to the vertical rib. 本発明に係る定着鋼板を縦リブに取り付けた例(縦リブの端部に定着鋼板を載せて取り付けた場合)を示した図である。It is the figure which showed the example (when attaching a fixing steel plate on the edge part of a vertical rib) and attaching the fixing steel plate which concerns on this invention to the vertical rib.

符号の説明Explanation of symbols

1 主桁
2 縦リブ
3 スキンプレート
4 棒状鋼材
5 継手板
6 中詰めコンクリート
7 縦リブの棒状鋼材挿通用開口部
7a 凹状開口部
8 幅止め材(主桁間に配置する場合)
9 幅止め材(主桁の外側から囲むように配置する場合)
10 スキンプレートと縦リブの溶接部
11 ポジショナー
12 組み立て船型治具(または仮組み治具)
13 合成セグメント
14 内縁側棒状鋼材
15 外縁側棒状鋼材
16 定着鋼板
17 縦リブ(定着鋼板を用いるタイプ)
18 定着鋼板を用いた場合の嵩上げ高さ
19 セグメント正規の幅
20 内縁側の主桁を広げた後のセグメントの幅
21 セグメント(主桁)内縁側
22 セグメント(主桁)外縁側
23 シャコ万
24 溶接ロボットのトーチ
25 船型治具の中側のスキンプレート設置用桁
26 船型治具の外側の主桁仮固定用板材
27 船型治具のスキンプレート設置用桁と主桁仮固定用板材の繋ぎ材
28 縦リブ設定用補助治具
29 ポジショナーの船型治具受け台
30 定着鋼板と縦リブとの溶接部
31 ポジショナーの基板
32 ポジショナーの支柱
33 ポジショナーの回転盤
34 定着鋼板の開先溶接
35 定着鋼板の隅肉溶接
DESCRIPTION OF SYMBOLS 1 Main girder 2 Vertical rib 3 Skin plate 4 Bar-shaped steel material 5 Joint plate 6 Filled concrete 7 Opening part for insertion of vertical steel bar-shaped steel material 7a Recessed opening 8 Width stop material (when arranged between main beams)
9 Width stop material (when placed so as to surround from the outside of the main beam)
10 Welded part of skin plate and vertical rib 11 Positioner 12 Assembly ship type jig (or temporary assembly jig)
13 Composite segment 14 Inner edge side bar-shaped steel material 15 Outer edge side bar-shaped steel material 16 Fixed steel plate 17 Vertical rib (type using fixed steel plate)
18 Raised Height When Using Fixed Steel Plate 19 Segment Normal Width 20 Segment Width After Expanding Inner Edge Side Main Girder 21 Segment (Main Girder) Inner Edge Side 22 Segment (Main Girder) Outer Edge Side 23 Welding robot torch 25 Girder for installing the skin plate on the inner side of the hull jig 26 Main plate for temporarily fixing the main girder outside the hull jig 27 Connecting material for the girder for setting the skin plate of the hull jig and the main girder temporary fixing plate 28 Auxiliary jig for setting longitudinal ribs 29 Positioner hull jig pedestal 30 Welded part between fixing steel plate and vertical rib 31 Positioner substrate 32 Positioner column 33 Positioner turntable 34 Welding welding of fixing steel plate 35 Fixing steel plate groove 35 Fillet welding

Claims (7)

主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
縦リブとスキンプレートとを本溶接した後に棒状鋼材を縦リブの開口部に挿通し、その後、鋼殻を一体化して最後に中詰コンクリートを充填する工程を有し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする合成セグメントの製造方法。
A steel plate with one or more vertical ribs with a main girder, joint plate, skin plate, and opening is installed to cross the opening of the vertical ribs and filled with concrete. In the method for producing a synthetic segment,
After the main welding of the vertical rib and the skin plate, the rod-shaped steel material is inserted into the opening of the vertical rib, and then the steel shell is integrated and finally filled with filled concrete,
A synthetic segment manufacturing method, wherein welding is performed such that the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.
主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
スキンプレートに主桁を仮付け溶接し、開口部を有する縦リブをスキンプレートに本溶接し、棒状鋼材を縦リブの開口部に挿通し、継手板を主桁またはスキンプレートの少なくともいずれかに仮溶接し、その後、スキンプレートと主桁、スキンプレートと継手板、縦リブと主桁、及び主桁と継手板を本溶接して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする合成セグメントの製造方法。
A steel plate with one or more vertical ribs with a main girder, joint plate, skin plate, and opening is installed to cross the opening of the vertical ribs and filled with concrete. In the method for producing a synthetic segment,
Temporarily weld the main girder to the skin plate, fully weld the vertical rib with the opening to the skin plate, insert the bar steel material into the opening of the vertical rib, and connect the joint plate to at least one of the main girder or the skin plate Temporarily welded, and then the steel plate and main girder, skin plate and joint plate, vertical rib and main girder, and main girder and joint plate were welded together to form an integrated steel shell, and finally the concrete inside the steel shell. Having a process of placing,
A synthetic segment manufacturing method, wherein welding is performed such that the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.
主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ仮付け溶接して組み立て、主桁のたわみ防止用幅止め材を、残りの継手板の取付位置から残りの継手板に一番近い縦リブの取り付け位置の間に主桁間に渡って設置し、主桁、縦リブ、片側の継手板、及びスキンプレートをそれぞれ本溶接した後、主桁のたわみ防止用幅止め材を外した後に縦リブの開口部に棒状鋼材を挿通する工程、又は縦リブの開口部に棒状鋼材を挿通した後に主桁のたわみ防止用幅止め材を外す工程のいずれか一方の工程の後、残った継手板を本溶接して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする合成セグメントの製造方法。
A steel plate with one or more vertical ribs with a main girder, joint plate, skin plate, and opening is installed to cross the opening of the vertical ribs and filled with concrete. In the method for producing a synthetic segment,
The main girder, vertical rib, one joint plate, and skin plate are each assembled by tack welding, and the main girder's deflection prevention width stopper is closest to the remaining joint plate from the mounting position of the remaining joint plate. Installed across the main girders between the installation positions of the vertical ribs, and after main welding the main girders, vertical ribs, joint plate on one side, and skin plate, respectively, removed the width stoppers for preventing deflection of the main girders. Remained after either step of inserting the rod-shaped steel material into the opening of the longitudinal rib later, or removing the width stopper for preventing the main girder from being inserted after the insertion of the rod-shaped steel material into the opening of the longitudinal rib The joint plate is welded and integrated into a steel shell, and finally the concrete is placed inside the steel shell,
A synthetic segment manufacturing method, wherein welding is performed such that the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.
主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ仮付け溶接して組み立て、主桁のたわみ防止用幅止め材を、残りの継手板の取付位置から残りの継手板に一番近い縦リブの取り付け位置の間に主桁間に渡って設置し、主桁、縦リブ、片側の継手板、及びスキンプレートをそれぞれ本溶接した後、縦リブの開口部に棒状鋼材を挿通し、その後、残りの継手板を本溶接してから主桁のたわみ防止用幅止め材を外して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする合成セグメントの製造方法。
A steel plate with one or more vertical ribs with a main girder, joint plate, skin plate, and opening is installed to cross the opening of the vertical ribs and filled with concrete. In the method for producing a synthetic segment,
The main girder, vertical rib, one joint plate, and skin plate are assembled by tack welding, and the main girder's deflection prevention width stopper is closest to the remaining joint plate from the mounting position of the remaining joint plate. Installed between the main girders between the installation positions of the vertical ribs, and after welding the main girders, the vertical ribs, the joint plate on one side, and the skin plate, respectively, insert a bar-shaped steel material into the opening of the vertical ribs, Then, after the remaining joint plate is fully welded, the width stop material for preventing deflection of the main girder is removed to form an integrated steel shell, and finally a step of placing concrete inside the steel shell,
A synthetic segment manufacturing method, wherein welding is performed such that the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.
主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントの製造方法において、
主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ仮付け溶接し、トンネル内縁側に凹状開口部を有する縦リブに棒状鋼材を挿通し、凹状の開口部を塞ぐように定着鋼板を縦リブに本溶接し、その後、主桁、縦リブ、片方の継手板、及びスキンプレートをそれぞれ本溶接して一体化した鋼殻とし、最後に鋼殻内部にコンクリートを打設する工程を有し、
前記定着鋼板を縦リブに溶接する前に、定着鋼板の溶接による縦リブの溶接収縮分だけ主桁内縁側間隔を広げて主桁をスキンプレートに仮付け溶接し、
各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満となるように溶接することを特徴とする合成セグメントの製造方法。
A steel plate with one or more vertical ribs with a main girder, joint plate, skin plate, and opening is installed to cross the opening of the vertical ribs and filled with concrete. In the method for producing a synthetic segment,
The main girder, vertical rib, one joint plate, and skin plate are tack welded to each other, and a steel rod is inserted into the vertical rib having a concave opening on the inner edge of the tunnel, and the fixing steel plate is attached so as to close the concave opening. After the main welding to the vertical rib, the main girder, the vertical rib, one joint plate, and the skin plate are each main welded to form an integrated steel shell, and finally there is a step of placing concrete inside the steel shell. And
Before welding the fixing steel plate to the longitudinal rib, the main girder is temporarily welded to the skin plate by expanding the inner side of the main girder by the welding shrinkage of the longitudinal rib due to welding of the fixing steel plate
A synthetic segment manufacturing method, wherein welding is performed such that the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.
前記棒状鋼材を前記合成セグメント用の鋼殻内に挿入する際、合成セグメント用の鋼殻を組み立て治具と共に角度調整可能なポジショナーの上に載置して固定し、ポジショナーを所定の角度に調整した後に、棒状鋼材を合成セグメント用の鋼殻内に挿入することを特徴とする請求項1〜4のいずれかの1項に記載の合成セグメントの製造方法。   When inserting the rod-shaped steel material into the steel shell for the synthetic segment, place the steel shell for the synthetic segment on the positioner with adjustable angle together with the assembly jig, and adjust the positioner to a predetermined angle. The method for producing a synthetic segment according to any one of claims 1 to 4, wherein the bar-shaped steel material is inserted into a steel shell for the synthetic segment after the process. 主桁、継手板、スキンプレート、及び開口部を有する1枚又は2枚以上の縦リブを備えた鋼殻に、棒状鋼材を縦リブの開口部に交差して設置し、中詰めコンクリートを充填してなる合成セグメントであって、各縦リブにおけるスキンプレートとの溶接部の長さの合計がセグメント幅の5%以上65%未満であることを特徴とする合成セグメント。   A steel plate with one or more vertical ribs with a main girder, joint plate, skin plate, and opening is installed to cross the opening of the vertical ribs and filled with concrete. A combined segment, wherein the total length of the welded portion of each vertical rib with the skin plate is 5% or more and less than 65% of the segment width.
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JP2011047265A (en) * 2009-07-30 2011-03-10 Nippon Steel Corp Segment and method for manufacturing the same
WO2014077094A1 (en) * 2012-11-13 2014-05-22 キャタピラー エス エー アール エル Welded structure and machinery
JP2020026683A (en) * 2018-08-13 2020-02-20 Jfe建材株式会社 Jig for assembling segment and method of manufacturing segment
JP6997353B1 (en) * 2021-08-26 2022-01-17 Khファシリテック株式会社 Manufacturing method of steel segment

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Publication number Priority date Publication date Assignee Title
JP2011047265A (en) * 2009-07-30 2011-03-10 Nippon Steel Corp Segment and method for manufacturing the same
WO2014077094A1 (en) * 2012-11-13 2014-05-22 キャタピラー エス エー アール エル Welded structure and machinery
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JP2020026683A (en) * 2018-08-13 2020-02-20 Jfe建材株式会社 Jig for assembling segment and method of manufacturing segment
JP6997353B1 (en) * 2021-08-26 2022-01-17 Khファシリテック株式会社 Manufacturing method of steel segment

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