JP2009083407A - Production process of composite segment - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce cost by saving on labor and time required for production. <P>SOLUTION: A composite segment 1 is produced by arranging a steel hull 2 composed of a skin plate 8, a main steel member 9, etc. in a mold form 20, and filling a concrete 3 in the mold form 20 implanted with the steel hull 2. Thus produced composite segment 1 makes a product with a concrete forming surface built on the configuration of mold form 20 so that the precision of the composite segment 1 is secured by dimensional precision of the mold form 20, regardless of an error of working accuracy of the steel hull 2. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a synthetic segment formed from a steel shell and concrete in a substantially arc plate shape.

Conventionally, in a shield construction method in which a tunnel is formed by constructing a cylindrical wall body by connecting a plurality of arc-plate-like segments in the circumferential direction and the axial direction while excavating a drill hole in a natural ground, for example, concrete Three types of segments are known: a segment made of steel, a steel (steel) segment, and a synthetic segment using a combination of steel (steel) and concrete. Among these segments, the synthetic segment is generally manufactured by including an arc plate frame (steel shell) made of steel and filling the steel shell with concrete (for example, Patent Document 1). And Patent Document 2).

The steel shell of the composite segment is provided with an outer peripheral side steel plate curved in the circumferential direction of the tunnel on the outer peripheral side of the arc plate frame, and a pair of main girders are welded to both side edges forming the long side of the outer peripheral side steel plate. A pair of joint plates are fixed by welding or the like to both side edges forming short sides, and the inner peripheral side facing the outer peripheral steel plate is opened.
And such a synthetic segment has a steel shell arranged with the outer side steel plate on the bottom and the opening side on the top, segment joints etc. are arranged at predetermined positions of the steel shell, and the concrete is placed in the steel shell from the opening. It is manufactured by filling.
JP-A-5-248182 JP 2000-34897 A

However, the conventional synthetic segment manufacturing method has the following problems.
That is, in the conventional manufacturing method, since the steel shell is used as a substitute for the formwork, the processing accuracy of the steel shell becomes the product accuracy of the segment, and it is necessary to ensure the dimensional accuracy for the steel shell. Therefore, if there is a processing error in the steel shell, there arises a problem that the position and accuracy of the segment joint arranged in the steel shell cannot be secured. Furthermore, when the dimensional accuracy of the steel shell decreases, when the synthetic segments are joined together, the joint surfaces do not evenly contact with each other, causing damage such as cracks or chips, or gaps between the two, resulting in water leakage. There was a risk of problems such as.
As described above, since it is necessary to secure the dimensional accuracy of the steel shell one by one for each synthetic segment, there is a problem in that it takes time and effort and increases the cost.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a method for manufacturing a synthetic segment that can reduce costs by reducing labor and time for manufacturing.

In order to achieve the above object, in the synthetic segment manufacturing method according to the present invention, a synthetic segment formed in a substantially arc plate shape from a steel shell and concrete in which a steel material is exposed on at least a part of the surface of the segment. A manufacturing method is characterized by having a step of arranging a part or the whole of a steel shell in a mold and a step of filling concrete into a mold in which the steel shell is arranged.
In this invention, a synthetic segment is manufactured by arrange | positioning at least one part or the whole of a steel shell to a formwork, filling concrete in the formwork, and demolding after solidification of concrete. And the manufactured synthetic segment turns into a product which has a concrete formation surface based on the shape of a formwork. Therefore, the product accuracy of the segment can be ensured by the dimensional accuracy of the mold, regardless of the error due to the processing accuracy of the steel shell.

Moreover, in the manufacturing method of the synthetic segment which concerns on this invention, it is preferable that the steel material exposed in a part of surface of a synthetic segment is joined to the synthetic segment after demolding.
In the present invention, since the steel shell formed by separating the steel material exposed on a part of the surface of the composite segment is disposed in the mold, the concrete is formed from the opening formed at the position where the separated steel material is located. Therefore, it is not necessary to provide a filling port for filling concrete in the mold, for example.

According to the synthetic segment manufacturing method of the present invention, at least a part or the whole of the steel shell is placed in the mold and is manufactured by placing concrete in the mold. Regardless, the product accuracy of the segment is ensured by the dimensional accuracy of the mold. Therefore, it is only necessary to secure the dimensional accuracy for a mold that can manufacture a large number of synthetic segments, and it is not necessary to ensure the dimensional accuracy of the steel shell for each synthetic segment as in the prior art. The labor and time are reduced, and the manufacturing cost can be reduced.
And the product accuracy of the synthetic segment is ensured by the formwork, and since there is no variation in the dimensional accuracy of the synthetic segment to be manufactured, it is possible to prevent breakage such as cracks and chips when joining the segments. Further, it is possible to improve the water stoppage at the joint surface. In addition, the position accuracy of the joint can be ensured by positioning the segment joint with respect to the formwork in which the dimensional accuracy is ensured.

Hereinafter, a first embodiment of a synthetic segment manufacturing method according to the present invention will be described with reference to FIGS.
1 is a perspective view of a synthetic segment according to the first embodiment of the present invention, FIG. 2 is a cross-sectional view taken along line AA of the synthetic segment shown in FIG. 1, and FIG. 3 is a skin in a steel shell in the synthetic segment shown in FIG. FIG. 4A to FIG. 4C are longitudinal sectional views showing the manufacturing process of the synthetic segment according to the first embodiment.

As shown in FIG. 1, the composite segment 1 obtained by the manufacturing method according to the first embodiment forms a tunnel covering body that forms a cylindrical wall body constructed on the inner wall of the tunnel by, for example, a shield method. A substantially rectangular plate-like shape is curved into a substantially cylindrical peripheral surface shape, and as shown in FIG. 2, it has a steel shell 2 made of steel and a concrete 3 filled therein. Yes.

And, in the circumferential direction joint surfaces 4 and 4 which are side surfaces on the short side side (side side along the axial direction of the tunnel) of the composite segment 1, an inter-segment joint such as a bolt box for connection in the circumferential direction of the tunnel is provided. 5 is provided. In addition, an inter-ring joint 7 such as a bolt box for coupling in the axial direction of the tunnel is provided on the tunnel direction joint surface 6 which is a side surface on the long side (side along the circumferential direction of the tunnel). . 2 and the subsequent drawings, the inter-segment joint 5 and the inter-ring joint 7 are omitted.

As shown in FIGS. 1 to 3, the steel shell 2 has a skin plate 8 that is curved and welded to the outer peripheral surface located on the natural ground side in a state where the synthetic segment 1 is mounted in the tunnel, and is welded into a cylindrical peripheral surface shape. And a pair of main steel materials 9, 9 whose long sides are curved in a substantially arc plate shape and whose cross section (cross section along the tunnel axis direction) forms a substantially rectangular shape. The pair of main steel materials 9 and 9 are arranged in three sets, each of which is similarly curved in parallel with a predetermined interval in the tunnel axis direction. And the both-sides edge part in the long side direction (circumferential direction of a tunnel) of a pair of main steel materials 9 and 9 is provided so that it may correspond to the circumferential direction joining surfaces 4 and 4 and may become flush. In addition, in FIG. 1, the main steel material 9 exposed to the circumferential direction joint surface 4 is abbreviate | omitted.

And as shown in FIG. 3, the main steel materials 9 and 9 which oppose the thickness direction (radial direction of a tunnel) of the synthetic | combination segment 1 are mutually connected by the some connection member 10, 10, ... which makes flat form. . A plurality of the connecting members 10 are arranged along the longitudinal direction of the main steel materials 9, 9 (the circumferential direction of the composite segment 1).
Moreover, as shown in FIG. 2, the skin plate 8 is being fixed to the outer peripheral surface 9a of the main steel material 9 located in the outer peripheral side among a pair of main steel materials 9 and 9 by welding. In addition, the inner peripheral surface 9b of the main steel material 9 located on the inner peripheral side is also embedded in the concrete 3 that forms the composite segment 1.

Next, the structure in the synthetic | combination segment 1 by this 1st embodiment is as having mentioned above, Next, the manufacturing method is demonstrated based on FIG.
The synthetic segment 1 shown in FIG. 4 shows a manufacturing process by a so-called mountain-placed concrete placing method.
As shown in FIG. 4 (a), in this manufacturing process, with the outer peripheral surface (that is, the skin plate 8) on the upper side and the inner peripheral surface on the lower side, the substantially central portion in the longitudinal direction of the composite segment 1 is the most. A mold 20 for manufacturing the composite segment 1 in a high position is used.

The mold frame 20 forms a bottom board portion 20a that closes the inner peripheral surface of the composite segment 1 in an arc shape, and the circumferential joint surfaces 4 and 4 and the tunnel joint surfaces 6 and 6 shown in FIG. The opening 20c is formed in the outer peripheral surface part in which the skin plate 8 is arrange | positioned. The opening 20 c becomes a filling port for the concrete 3.

As a manufacturing method, a pair of main steel materials 9 and 9 are previously formed in a state of being connected by a plurality of connecting members 10, 10,..., And the main steel material 9 and the skin plate 8 are separated without being joined. . And as shown to Fig.4 (a), while arrange | positioning the main steel materials 9 and 9 in the formwork 20, each joint 5 and 7 shown in FIG. 1 is arrange | positioned to the joint surfaces 4 and 6 of the synthetic | combination segment 1. FIG. In this manner, the side plate portion 20b is detachably attached to a predetermined portion.

And as shown in FIG.4 (b), the concrete 3 is poured and filled from the opening part 20c of the formwork 20. As shown in FIG. The top surface of the filled concrete 3 is flush with the curvature of the outer peripheral surface 9a of the main steel material 9 located on the outer peripheral side. Here, in the placing method according to the first embodiment, since filling is performed from above the mold 20, air bubbles contained in the concrete 3 escape from the opening 20 c located above the mold, so that the mold 20 It is designed not to remain inside.

  Subsequently, as shown in FIG. 4 (c), when the filled concrete 3 is demolded at an appropriate time when solidified, a product having a concrete forming surface based on the shape of the mold 20 is obtained. And the manufacture of the synthetic segment 1 is completed by joining the skin plate 8 to the outer peripheral surface 9a of the main steel material 9 on the outer peripheral side by fixing means such as welding.

Thus, in this manufacturing method, since the steel shell 2 in a state where the skin plate 8 (steel material) exposed on a part of the surface of the composite segment 1 is separated is disposed in the mold frame 20, the separation is performed. Since the concrete 3 can be filled into the mold 20 from the opening 20c formed at the location where the skin plate 8 is positioned, for example, it is not necessary to provide a filling port for filling the concrete in the mold 20 It has become.

In the synthetic segment manufacturing method according to the first embodiment described above, the concrete shell 3 is placed by placing the steel shell 2 on the mold frame, so that the mold frame 20 regardless of errors due to the processing accuracy of the steel shell 2. The product accuracy of the composite segment 1 is ensured by the dimensional accuracy. Therefore, it is only necessary to secure the dimensional accuracy for the mold 20 that can produce a large number of synthetic segments 1, 1,..., And ensure the dimensional accuracy for each steel shell of each synthetic segment as in the past. This eliminates the need to do so, reducing the labor and time required for manufacturing, and reducing the manufacturing cost.

And since the product accuracy of the synthetic segment 1 is ensured by the mold 20, and the dimensional accuracy of the synthetic segment 1 to be manufactured does not vary, damage such as cracks or chipping occurs when the synthetic segments 1 and 1 are joined together. Can be prevented and the water stoppage at the joint surface can be improved. In addition, the position accuracy of the joint can be ensured by positioning the segment joint with respect to the formwork in which the dimensional accuracy is ensured.

Next, second to fourth embodiments of the present invention will be described with reference to FIGS. 5 to 10 and the like, but the same reference numerals are used for members or parts that are the same as or similar to those of the above-described embodiments. The description is omitted, and a configuration different from the embodiment will be described.
FIG. 5 is a perspective view showing a synthetic segment manufacturing process according to the second embodiment, and FIG. 6 is a cross-sectional view taken along line BB of the synthetic segment manufacturing process shown in FIG.

As shown in FIGS. 5 and 6, the method for manufacturing the synthetic segment 1 </ b> A manufactured according to the second embodiment is a so-called concrete placing method by so-called hill driving similar to the first embodiment described above. . In the first embodiment shown in FIG. 4, the concrete 3 is poured into the mold 20 from the opening 20c of the mold 20 with the skin plate 8 separated at the time of placing the concrete. In the second embodiment, the skin plate 8 is preliminarily disposed on the mold 30 before the concrete is placed. That is, in the mold 30 used in the second embodiment, the concrete 3 is applied to the side plate portion 31b located on one tunnel direction joint surface 6 (see FIG. 1) on the tunnel axis direction side of the composite segment 1A. A filling port 31 for filling is provided. And the air vent pipe 32 is provided in the both-sides board part 30b and 30b in which the filling port 31 was formed.

  The filling port 31 is formed at a substantially central position of the side plate portion 30b so as to penetrate the side plate portion 30b in the thickness direction. An appropriate number of air vent pipes 32 are provided in a state where the end portion 32a is disposed at a position slightly away from the inner surface of the skin plate 3 and the inside and the outside of the mold 30 are communicated with each other.

As shown in FIG. 6, in the manufacturing method, a pair of main steel materials 9, 9 are connected in advance by a plurality of connecting members 10, 10,..., And the skin plate 8 is fixed to the outer peripheral surface 9 a of the main steel material 9. The steel shell 2 is formed in the state, the steel shell 2 is arranged in the mold 30, and the side plate portions are arranged so that the joints 5 and 7 shown in FIG. 1 are arranged on the joint surfaces 4 and 6 of the composite segment 1. It attaches to the predetermined part of 30b so that attachment or detachment is possible. At this time, the air vent pipe 32 is also arranged so that the end portion 32a is at the predetermined position described above.

Subsequently, the concrete 3 is poured into the mold 30 from the filling port 31 and filled. In the second embodiment, it is preferable to use fluid concrete. At this time, fine bubbles contained in the concrete 3 filled in the mold 30 rise toward the inner surface of the skin plate 8. Then, the injected concrete 3 gradually rises in a mountain shape immediately below the filling port 31, and when filled up to the point where the filling port 31 is blocked, the bubbles remain along the inner surface of the skin plate 8 without any passage. However, the bubbles escape to the outside of the mold 30 through the air vent pipe 32. Therefore, there is no unfilled portion where voids are formed in the vicinity of the inner surface of the skin plate 8, and the high-quality synthetic segment 1A in which the filled concrete 3 and the skin plate 8 are in close contact with each other can be manufactured.

After the concrete 3 is placed, a filler (not shown) is poured into the filling port 31 to close it, and the outlet 32b of the air vent pipe 32 is closed by, for example, welding means. Next, the mold is removed at an appropriate time when the filled concrete 3 is solidified, and a filler (not shown) such as mortar is injected into the air vent pipe 32 embedded in the synthetic segment 1A to complete the hole.

In the manufacturing method of the synthetic segment 1A according to the second embodiment, the product accuracy of the synthetic segment 1A is ensured by the dimensional accuracy of the mold 30 as in the manufacturing method according to the first embodiment, and the steel shell of the synthetic segment 1A is secured. Since it is not necessary to ensure the dimensional accuracy every two, it is possible to reduce the labor and time for manufacturing and to reduce the manufacturing cost.

Next, FIG. 7 is a perspective view showing the manufacturing process of the synthetic segment according to the third embodiment, and FIG. 8 is a sectional view taken along the line CC of the manufacturing process of the synthetic segment shown in FIG.
The method for manufacturing the composite segment 1B according to the third embodiment shown in FIGS. 7 and 8 is a so-called concrete casting method by boat driving, and the short side (FIG. 1) of the composite segment 1B with the skin plate 8 facing downward. Is produced in a state where one end of the circumferential joining surface 4) shown in FIG.

The mold 40 forms a bottom board portion 40a formed in an arc shape along the skin plate 8 of the composite segment 1B, and the circumferential direction joint surfaces 4 and 4 and the tunnel direction joint surfaces 6 and 6 shown in FIG. The opening 40c is formed in the position used as the inner peripheral surface of the synthetic | combination segment 1B. And the metal mesh 42 is arrange | positioned along the opening surface in the opening part 40c. Then, the concrete 3 is filled into the mold from the filling port 41 provided at the highest position of the mold 40 (the upper side plate portion 40b) and placed.

As shown in FIG. 8, in the manufacturing method, the steel shell 2 is formed in a state in which the pair of main steel materials 9, 9 and the skin plate 8 are integrated in the same manner as in the second embodiment. The steel shell 2 is disposed on the side plate 40b so that the joints 5 and 7 shown in FIG. The wire mesh 42 is arranged along the position of the inner peripheral surface of the synthetic segment 1B in the portion 40c. Subsequently, the concrete 3 is poured into the mold 40 from the filling port 41 of the mold 40 and filled.

At this time, the upper surface of the filled concrete 3 is placed in a shape along the wire mesh 42, with the wire mesh 42 serving as a formwork. Here, in the placing method according to the third embodiment, since filling is performed from the highest position of the mold 40, the filling port 41 is used to vent air bubbles contained in the concrete 3 while filling the concrete 3. It does not accumulate in the mold 40.

Then, after the concrete 3 is placed, the composite segment 1B can be completed by demolding at an appropriate time when the filled concrete 3 is solidified.
In the manufacturing method of the synthetic segment 1B according to the third embodiment, the same effects as those of the manufacturing methods according to the first and second embodiments described above can be obtained.

Next, FIG. 9 is a perspective view showing the manufacturing process of the synthetic segment according to the fourth embodiment, and FIG. 10 is a sectional view taken along the line DD of the manufacturing process of the synthetic segment shown in FIG.
The method for manufacturing the composite segment 1C according to the fourth embodiment shown in FIGS. 9 and 10 is a concrete placing method by vertical casting, and both long sides of the composite segment 1 with the skin plate 8 facing substantially in the horizontal direction. (Tunnel-direction joint surfaces 6 and 6 shown in FIG. 1) are set in the vertical direction, and one of the short sides (circumferential-direction joint surfaces 4 and 4 shown in FIG. It is a method manufactured with the surface side inclined.

The mold 50 forms an inner peripheral plate portion 50a for closing the inner peripheral surface of the composite segment 1C so as to form an arc shape, and the circumferential joint surfaces 4 and 4 and the tunnel joint surfaces 6 and 6 shown in FIG. The side plate portion 50b is closed, and an opening portion 50c is formed in the outer peripheral surface portion where the skin plate 8 is disposed. A filling port 51 for filling the concrete 3 is provided at the highest position of the one side plate portion 50b located on the short side of the composite segment 1C. And the long side side plate part 50b, 50b located above the synthetic segment 1C is provided with an air vent pipe 52 penetrating in the thickness direction.

As shown in FIG. 10, in the manufacturing method according to the fourth embodiment, a pair of main steel materials 9, 9 and a skin plate 8 are integrated in the same manner as in the second and third embodiments. The shell 2 is formed, and the steel shell 2 is disposed in the mold 50, and the side plate portion 50b has a predetermined shape so that the joints 5 and 7 shown in FIG. 1 are disposed on the joint surfaces 4 and 6 of the composite segment 1C. Removably attach to the location. Subsequently, the concrete 3 is poured into the mold 50 from the filling port 51 of the mold 50 and filled.

Here, in the placing method according to the fourth embodiment, since the filling is performed from the high position of the side plate portion 50b, the portion up to the place where the filling port 51 is closed is included in the concrete 3 together with the filling of the concrete 3. When the air bubbles are vented and filled up to the point where the filling port 51 is blocked, the air bubbles escape to the outside of the mold 50 through the air vent pipe 52.

Then, after the concrete 3 is placed, the composite segment 1C can be completed by demolding at an appropriate time when the filled concrete 3 is solidified.
In the manufacturing method of the synthetic segment 1C according to the fourth embodiment, the same effects as the manufacturing methods according to the first to third embodiments described above can be obtained.

The first to fourth embodiments of the synthetic segment manufacturing method according to the present invention have been described above. However, the present invention is not limited to the above-described embodiments, and may be changed as appropriate without departing from the spirit of the present invention. Is possible.
For example, in the first to fourth embodiments, the steel shell 2 is composed of the skin plate 8, the main steel material 9, the connection member 10, etc., but is not limited to this, for example, the circumferential joining surface 4 and a steel shell provided with a steel plate for adhering a water-stopping member to a part of the joint surface 6 in the tunnel direction, and a steel shell provided with a skin plate on the inner peripheral surface as well as the outer peripheral surface of the synthetic segment, It doesn't matter.

Further, in the first and second embodiments, a concrete placing method by mountain driving, and in the third embodiment, one circumferential joint surface 4 is the highest with the inner peripheral surface side of the synthetic segment 1B facing upward. However, the present invention is not limited to these placement methods. However, the present invention is not limited to these placement methods.

Further, the arrangement, the cross-sectional shape, the arrangement quantity, etc. of the filling ports 31, 41, 51 and the air vent pipes 32, 52 are not limited to the present embodiment, but the shape of the synthetic segment to be manufactured, the structure of the steel shell, the mold What is necessary is just to set arbitrarily according to conditions, such as a form of a frame.
Furthermore, it is not limited to the arrangement, shape, and number of places of the main steel material 9 and the connecting member 10, for example, as other main steel materials, I-shaped, H-shaped, L-shaped, T-shaped, etc. are adopted in cross-sectional shape. The connecting member 9 is not limited to a flat plate shape, and may have a lattice structure in which a plurality of steel materials are arranged in a substantially V shape.

It is a perspective view of the synthetic segment by 1st embodiment of this invention. It is the sectional view on the AA line of the synthetic segment shown in FIG. It is a disassembled perspective view of the state which isolate | separated the skin plate in the steel shell in the synthetic | combination segment shown in FIG. (A) thru | or (c) is a longitudinal cross-sectional view which shows the manufacturing process of the synthetic | combination segment by 1st embodiment. It is a perspective view which shows the manufacturing process of the synthetic segment by this 2nd embodiment. FIG. 6 is a cross-sectional view of the synthetic segment manufacturing process shown in FIG. 5 taken along the line BB. It is a perspective view which shows the manufacturing process of the synthetic segment by this 3rd embodiment. It is CC sectional view taken on the line of the manufacturing process of the synthetic segment shown in FIG. It is a perspective view which shows the manufacturing process of the synthetic segment by this 4th embodiment. FIG. 10 is a sectional view taken along line DD of the manufacturing process of the synthetic segment shown in FIG. 9.

Explanation of symbols

1, 1A, 1B, 1C Composite segment 2 Steel shell 3 Concrete 4 Circumferential joint surface 6 Tunnel direction joint surface 8 Skin plate 9 Main steel material 20, 30, 40, 50 Formwork 31, 41, 51 Filling port

Claims (2)

A method for producing a synthetic segment formed in a substantially arc plate shape from a steel shell and concrete in which a steel material is exposed on at least a part of the surface of the segment,
Arranging a part or the whole of the steel shell in a mold,
Filling concrete into the formwork in which the steel shell is disposed;
A method for producing a synthetic segment, comprising:   The method for manufacturing a synthetic segment according to claim 1, wherein the steel material exposed on a part of the surface of the synthetic segment is joined to the synthetic segment after demolding.

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