JP4436234B2 - Manufacturing method for segments with refractory material - Google Patents

Description

  The present invention relates to a segment made of concrete, for example, attached as an lining material to the inner surface of an excavated tunnel, and more particularly to a segment with a refractory material in which a refractory material is integrally provided on the inner peripheral surface thereof and a method for manufacturing the same.

  Conventionally, for example, a concrete segment is attached to the inner surface of an excavated tunnel as a lining material, and a refractory material is provided on the inner peripheral surface of the segment. FIG. 3 shows an example thereof, which is a configuration in which a large number of refractory plates 12 are arranged side by side on the inner peripheral surface of a concrete segment body 11 formed in a substantially arc shape in cross section.

  Also, as a method for manufacturing a segment with a refractory material as described above, when the segment body 11 as described above is formed into a predetermined shape with a mold or the like, the refractory material 12 is integrated at the same time. (See, for example, Patent Document 1 below).

  FIG. 4 shows an example. First, as shown in FIG. 4A, the lid 131 in the segment molding form 13 including a mold body 130 and a lid 131 formed in a predetermined substantially arc shape. In a state in which the refractory material is removed, the refractory material 12 formed in a predetermined shape in advance is disposed on the bottom of the mold body 130. In the case of the figure, a plurality of plate-like refractory materials 12 formed in a curved shape substantially the same as the inner peripheral surface of the segment main body 11 to be molded are arranged side by side on the bottom portion 130 a in the mold main body 130.

  In the state where the refractory material 12 is arranged on the bottom portion 130a in the mold body 130 as described above, reinforcing reinforcing bars are arranged in the mold 13 as necessary, and as shown in FIG. A cover 131 is placed on the upper opening of the mold body 130, and concrete for forming the segment body 11 is injected from a hole 131a formed in the cover 131. In the case of the figure, a concrete supply pump (not shown) The concrete is sequentially supplied into the mold 13 from the supply port 14a of the supply pipe 14 communicating with the above through the hole 131a.

  By injecting concrete into the mold 13 as described above and vibrating and forming as necessary, a segment body 11 having a predetermined shape is formed as shown in FIG. As shown in FIG. 3, when the refractory material 12 is integrally fixed to the inner peripheral surface (lower surface in the drawing) of the main body 11 and is taken out from the mold 13 after a predetermined curing period has elapsed. A segment with a refractory material 12 can be obtained. In addition, when the segment main body 11 is formed, as shown in FIG. 4A, if the refractory material 12 is provided with projections 15 and protrusions protruding toward the segment main body 11 in advance, the segment main body 11 and the fireproof material are formed. The material 12 can be integrated more firmly.

  However, the weight of concrete that is usually put into a mold for forming one segment is about 6 tons, and there are slight irregularities and distortions on the inner surface of the bottom of the refractory material 12 and the mold 13 on which it is placed. However, depending on the weight of the concrete, there was a risk that the refractory material 12 may be damaged due to local excessive force or excessive force. Further, in that case, it is impossible to confirm whether or not the refractory material 12 is damaged while the concrete is being put into the mold and during curing, and the yield is reduced because it must be confirmed after demolding.

  In addition, for a segment where the refractory material is damaged, the damaged refractory material must be peeled off and a new refractory material must be reattached to the segment body.To attach a refractory material to a segment body that has already been formed into a predetermined shape, for example, Post-installed anchors must be placed on the segment body, and the refractory material must be bolted to the anchors. This requires a lot of labor and time, and the bolts are exposed on the surface of the refractory material, so that the outer tube shape can be removed. There were problems such as damage. In addition, since joints are formed between adjacent refractory materials in one segment, the joint becomes a weak point of the fire-resistant structure, but all joints are processed into a complete fire-resistant structure. Was very time consuming.

Japanese Patent No. 3490907

  The present invention has been proposed in view of the above-mentioned problems, and a segment with a refractory material that can be easily and inexpensively manufactured without applying excessive force or excessive force due to the concrete weight to the refractory material. And it aims at providing the manufacturing method.

  In order to achieve the above object, a segment with a refractory material and a method for manufacturing the same according to the present invention are configured as follows. That is, the segment with a refractory material according to the present invention is integrally provided with a refractory material formed by covering and solidifying a predetermined thickness of a refractory material forming slurry on the surface of a segment body formed into a predetermined shape. Features. A mesh material can be interposed between the segment body and the refractory material as necessary.

Moreover, the manufacturing method of the segment with a refractory material according to the present invention includes a first step of forming a segment main body having a substantially arc-shaped cross section, a second step of arranging a mesh material on the inner peripheral surface of the segment main body, A flow-resistant refractory material forming slurry is poured onto the inner peripheral surface of the segment main body that is disposed upward and the mesh material is disposed, and is coated with a predetermined thickness to be solidified. A third step of integrally forming a refractory material having a predetermined thickness, and preferably a slurry for forming a refractory material having fluidity, with the addition of reinforcing fibers, and stirring and mixing It is characterized by. Moreover, the manufacturing method of the segment with a refractory material of the present invention includes a mold body having a substantially arc-shaped cross section arranged so that the inner peripheral surface side is on the top, and a lid arranged on the upper side of the mold body. A first step of pouring concrete into a configured segment forming mold, and forming a segment main body having a substantially arc-shaped cross section so that an inner peripheral surface of the segment main body faces up; and the upper lid body A second step of disposing the mesh material on the inner peripheral surface disposed upward of the segment main body, and the inner peripheral surface disposed of the segment main body upward and where the mesh material is disposed. The refractory material forming slurry having fluidity is poured, the refractory material formation slurry is coated to a predetermined thickness and solidified, and a refractory material having a predetermined thickness is integrally formed on the inner peripheral surface of the segment body. 3 steps Characterized in that it comprises a.

  In the segment with a refractory material and the manufacturing method thereof according to the present invention, the refractory material forming slurry is coated and solidified on the surface of the segment main body molded into a predetermined shape as described above, and the refractory material is integrally provided. Therefore, it becomes possible to easily and inexpensively manufacture the segment with the refractory material without applying excessive force or excessive force to the refractory material as in the conventional example.

  Hereinafter, the segment with a refractory material and the manufacturing method thereof according to the present invention will be specifically described based on the embodiments shown in the drawings.

  1A and 1B show an embodiment of a segment with a refractory material according to the present invention. FIG. 1A is a longitudinal sectional view thereof, and FIG. 1B is an enlarged view of a part thereof.

  The present embodiment is applied to a tunnel lining segment in the same manner as in FIG. 3, and the segment body 1 is formed in a substantially arc-shaped cross section with concrete in the same manner as described above, and a refractory forming slurry is formed on the inner peripheral surface thereof. Is integrally provided with a refractory material 2 formed by covering and solidifying a predetermined thickness. Although the material of the refractory material 2 is appropriate, for example, a material mainly composed of a cement-based material such as alumina cement can be used.

  A mesh material 4 is interposed between the segment body 1 and the refractory material 2 as necessary. In the case of the figure, the mesh material 4 made of a wire mesh or the like is interposed between the segment body 1 and the refractory material 2. The segment body 1 and the refractory material 2 are integrally fixed to each other through the mesh material 4. In the figure, reference numeral 5 denotes a fixing tool such as a bolt for fixing the mesh material 4 to the segment body 1.

  Next, an example of a manufacturing process in the case of manufacturing a segment with a refractory as described above will be described in order based on FIG. FIG. 2A shows a reinforcing bar in a segment forming mold 3 composed of a substantially arc-shaped mold body 30 and a lid 31 as needed, and a hole 31 a formed in the lid 31. Concrete is poured from above, and the segment main body 1 is shaped into a predetermined shape by exciting as necessary. The conventional mold 13 shown in FIG. 4 is formed so that the inner peripheral surface side of the segment main body 1 formed in a substantially arc shape is on the bottom. However, the mold 3 of this embodiment is a segment main body. In this configuration, the inner peripheral surface side of 1 is formed so as to face up.

  The segment body 1 molded into a predetermined shape as described above is cured until the mold 3 is in a state where it can be removed from the mold, and when it is cured to some extent, only the lid 31 is removed, and the surface of the segment body 1 ( The inner surface is coated with a slurry for forming a refractory material to a predetermined thickness to form a refractory material (refractory material layer) 2. In this case, it is necessary between the segment body 1 and the refractory material 2. Accordingly, when the mesh material 4 as described above is interposed, the segment body 1 and the refractory material 2 can be integrated more firmly.

In this embodiment, as shown in FIG. 2 (b), a mesh material 4 made of a wire mesh or the like is disposed on substantially the entire upper surface of the segment body 1 formed by the mold 3, and the mesh material 4 is the main material. In the embodiment, a fixing tool 5 such as a bolt is driven into the segment main body 1 in a state before a predetermined strength is expressed and fixed to the surface (inner peripheral surface) of the segment main body 1.

The surface of the segment body 1 on which the mesh material 4 is disposed, or the surface of the segment body 1 without the mesh material 4 being disposed, is coated with a slurry for forming a refractory material, and the coating method and the like are appropriate. However, in this embodiment, as shown in FIG. 2 (c), a slurry for forming a refractory material is poured into the surface of the segment body 1 from the supply port 6a of the supply pipe 6 communicating with a slurry supply pump (not shown). Thickness coating. As the refractory material forming slurry, a fluid material obtained by adding a heat-resistant aggregate, inorganic or organic reinforcing fiber or the like to a cement-based material such as alumina cement and stirring and mixing may be used.

  After covering the surface of the segment body 1 with the refractory material forming slurry as described above, the refractory material 2 is left as it is, or smoothed with a trowel or the like as necessary and then solidified. Form. Then, when the refractory material 2 is cured to some extent, the mold is removed and cured for a predetermined period of time, so that a segment with refractory material as shown in FIG. 1 can be obtained.

  As described above, in the present invention, the segment body 1 is molded in a predetermined shape in advance, and then the surface (inner peripheral surface) of the segment body 1 is coated with the refractory material forming slurry and solidified to integrally form the refractory material. By providing it to the fireproof plate, as in the case of pouring concrete after placing the fireproof material at the bottom of the segment molding formwork as in the prior art, it acts locally. Thus, the segment with the refractory material can be manufactured easily and inexpensively. The means for coating the surface of the segment body 1 with the slurry for forming the refractory material is not limited to pouring as described above, and it is covered by means such as spraying, coating, or placing according to the properties. You may do it.

  In addition, the conventional refractory material needs to be molded into a circular arc shape with a die or the like in advance along the curved surface of the circular arc segment, and the die must be manufactured according to a different radius for each type of tunnel. However, in the present invention, the mold itself for forming the refractory plate is not necessary, and the surface of the segment body 1 is curved along the curved surface of the segment body 1 simply by coating the surface of the segment body 1 with the refractory material forming slurry. The fire-resistant material can be easily and quickly formed. In addition, since the refractory material thus formed covers the inner surface of the segment and no joints are formed on the surface of the segment, the surface of the concrete segment is not exposed to weak points due to the joints. That is, the segment can be made to have a fireproof structure without exerting labor for joint processing as in the conventional manufacturing method.

  Furthermore, in the above-mentioned conventional manufacturing method, the refractory plate produced at the refractory plate manufacturing plant must be transported to the segment manufacturing plant and integrally formed with the segment, which incurs production costs and transportation costs for the refractory plate. However, in the present invention, it is not necessary to mold and transport the refractory plate into a predetermined shape in advance, and it can be integrally formed with the refractory plate for the extension of segment production. Can be made.

  In particular, the refractory material forming slurry is allowed to flow in a state where only the surface mold is removed, even if the mold is not attached until the segment body 1 molded into a predetermined shape exhibits a predetermined strength. Can be shortened. In addition, when performing the operation | work which coat | covers the slurry for refractory material formation, if the above mesh materials 4 are interposed between the said segment main body 1 and the refractory material 2, the said segment main body 1 and the refractory material 2 will be further In addition to being able to be firmly integrated, it is possible to more accurately enable the slurry to flow uniformly and to keep the thickness of the refractory material uniform.

  The segment main body 1 may be coated with the refractory material forming slurry after the mold 3 is completely removed, thereby increasing the working efficiency of the mold and improving the productivity. Further, when the segment main body 1 is formed, a protrusion for preventing the refractory material 2 from falling off is embedded on the surface (inner peripheral surface) side, or the refractory material forming slurry is coated after forming irregularities. You may make it do. In this case, a mesh material may be interposed between the segment body 1 and the refractory material 2 so as to be integrated.

  As described above, according to the present invention, it is possible to manufacture a segment with a refractory material with a high yield without damaging the refractory plate as in the prior art, and it is possible to attach a refractory material on the extension of the manufacturing process of the segment. This makes it possible to manufacture segments with refractory materials easily and inexpensively, which is extremely effective in industry.

(A) is a longitudinal cross-sectional view which shows one Embodiment of the segment with a refractory material by this invention, (b) is the one part enlarged view. (A)-(c) is process explanatory drawing which shows an example of the manufacturing method of the segment with a refractory material by this invention. (A) is a longitudinal cross-sectional view which shows an example of the conventional segment with a refractory material, (b) is the one part enlarged view. (A)-(c) is process explanatory drawing which shows an example of the manufacturing method of the conventional segment with a refractory material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Segment main body 2 Fireproof board 3 Formwork 30 Formwork main body 31 Cover body 4 Mesh material 5 Fixing tool

Claims (3)

A first step of forming a segment body having a substantially arc-shaped cross section;
A second step of arranging a mesh material on the inner peripheral surface of the segment body;
An inner peripheral surface of the segment main body that is disposed upwards and is coated with a predetermined thickness on the inner peripheral surface on which the mesh material is disposed, and is coated with a predetermined thickness to be solidified. A third step of integrally forming a predetermined thickness of the refractory material;
A method for producing a segment with a refractory material. The method for producing a segment with a refractory material according to claim 1, wherein the slurry for forming a refractory material having fluidity is obtained by adding reinforcing fibers and stirring and mixing. Concrete is poured into a mold frame for segment molding composed of a mold body having a substantially arc-shaped cross section disposed with the inner peripheral surface side facing up and a lid disposed on the upper side of the mold body, A first step of forming a segment main body having a substantially arc-shaped cross section so that the inner peripheral surface of the segment main body faces upward;
A second step of removing the upper lid and disposing a mesh material on the inner peripheral surface of the segment body that is disposed upward;
The refractory material forming slurry having fluidity is poured into the inner peripheral surface on which the segment main body is disposed upward and the mesh material is disposed, and the refractory material forming slurry is coated to a predetermined thickness and solidified. A third step of integrally forming a refractory material having a predetermined thickness on the inner peripheral surface of the segment body;
A method for producing a segment with a refractory material.

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