US20210215042A1 - Cast-in tunnel gasket and joining method - Google Patents
Cast-in tunnel gasket and joining method Download PDFInfo
- Publication number
- US20210215042A1 US20210215042A1 US16/074,046 US201716074046A US2021215042A1 US 20210215042 A1 US20210215042 A1 US 20210215042A1 US 201716074046 A US201716074046 A US 201716074046A US 2021215042 A1 US2021215042 A1 US 2021215042A1
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- United States
- Prior art keywords
- tunnel segment
- gasket
- joint
- tunnel
- film
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- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000005304 joining Methods 0.000 title description 11
- 238000005728 strengthening Methods 0.000 claims abstract description 30
- 238000004873 anchoring Methods 0.000 claims abstract description 19
- 238000005266 casting Methods 0.000 claims abstract description 5
- 238000005520 cutting process Methods 0.000 claims description 40
- 239000010408 film Substances 0.000 description 23
- 239000007787 solid Substances 0.000 description 5
- 238000007789 sealing Methods 0.000 description 4
- 230000001154 acute effect Effects 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000013536 elastomeric material Substances 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 239000010409 thin film Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000004821 Contact adhesive Substances 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/52—Joining tubular articles, bars or profiled elements
- B29C66/524—Joining profiled elements
- B29C66/5243—Joining profiled elements for forming corner connections, e.g. for making window frames or V-shaped pieces
- B29C66/52431—Joining profiled elements for forming corner connections, e.g. for making window frames or V-shaped pieces with a right angle, e.g. for making L-shaped pieces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0021—Combinations of extrusion moulding with other shaping operations combined with joining, lining or laminating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
- B29C65/54—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
- B29C65/542—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts by injection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/022—Mechanical pre-treatments, e.g. reshaping
- B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
- B29C66/02241—Cutting, e.g. by using waterjets, or sawing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
- B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/52—Joining tubular articles, bars or profiled elements
- B29C66/524—Joining profiled elements
- B29C66/5243—Joining profiled elements for forming corner connections, e.g. for making window frames or V-shaped pieces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/725—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs
- B29C66/7252—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs hollow-walled
- B29C66/72523—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs hollow-walled multi-channelled or multi-tubular
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D11/00—Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
- E21D11/38—Waterproofing; Heat insulating; Soundproofing; Electric insulating
- E21D11/385—Sealing means positioned between adjacent lining members
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/26—Sealing devices, e.g. packaging for pistons or pipe joints
- B29L2031/265—Packings, Gaskets
Definitions
- the present invention relates to an improved “cast-in” tunnel gasket and a method of joining such a tunnel gasket.
- Elastomeric (rubber) gaskets are used to seal segmentally formed tunnels; for example, against water ingress.
- the rubber gaskets are fitted between concrete tunnel segments.
- rubber tunnel gaskets were fitted into grooves pre-formed in the tunnel segments and secured with adhesive.
- An example of an existing cast-in tunnel gasket includes that disclosed in patent publication WO2013189491 (Datwyler), wherein a moulded product is produced in a shutter assembly. It is known to provide such anchored/“cast-in” tunnel seals as an alternative to inserting a seal in a pre-cast groove in the concrete using a contact adhesive.
- a “cast-in” tunnel segment gasket (TSG) has been found to offer advantages in reliability and eliminates the cost and inconvenience of using adhesives.
- “cast-in” tunnel segment gaskets are manufactured by encasing the segment gasket in concrete during the casting of the segments themselves. It is also known that it is advantageous to provide a gasket profile that allows for the significant forces that the concrete tunnel segments are to be placed under.
- the tunnel segment gasket comprises profiled geometries according to the expected deformation of the gasket under compression; for example including one or more longitudinal channels running therethrough and/or having “anchored” profiles with legs protruding therefrom. It is known that a cast-in tunnel gasket “collapses” into the groove into which it has formed during use, to close the gap between adjacent concrete tunnel segments.
- a solid corner join results from “shooting” rubber in at the corner joint, often termed a “shot-joint”, which then travels along the longitudinal channels in the adjoining gaskets.
- a solid, filled corner joint does not allow for any compression or movement of the joint; for example if the TSGs are not aligned perfectly or if there is ground movement after installation.
- existing solid corner TSG joints lead to excessive load building up at the corners, which will eventually lead the concrete segments attached thereto to crack.
- the gaskets will be not be securely held and leaks are very likely to occur.
- the cross-section or profile of the gasket is designed to take the strain of the load applied by the adjoining tunnel segments; that is, to minimise the closure forces exerted on the tunnel segments whilst securely sealing the tunnel.
- the present invention sets out to alleviate the problems described above by providing an improved tunnel segment gasket and an improved method of joining tunnel segment gaskets.
- the invention provides a tunnel segment gasket comprising a shaped profile having at least two anchoring legs for casting in to a tunnel segment; a plurality of longitudinally extending bores; a shot film joint and a strengthening element at the base of the gasket.
- base of the gasket refers to the face of the gasket between the two anchoring legs, which is external to the shot film joint.
- the strengthening element is shaped and positioned to increase the strength of the tunnel segment gasket at the joint.
- the strengthening element is a rhombus shape having a centre line parallel to the shot film joint.
- the strengthening element is integral with the shot film joint.
- the shot film joint is concealed within the tunnel segment gasket and the strengthening element is exposed at the base of the gasket.
- the configuration of the present invention provides much improved joint security for tunnel segment gaskets.
- the strengthening element acts, in use, as a “keying element” and protrudes from the shot film joint at the base of the main body of the shaped profile.
- the strengthening element of the profile does not affect the load characteristics of the gasket under compression.
- the strengthening element/“keying element” does not hinder the closure performance of the tunnel segments nor does it affect the load compressing the gasket, but provides a remarkably secure joint. It has been found that the security of the joint is remarkably improved and the risk of the gasket pulling apart at the joint and the joint failing is much reduced.
- the tunnel segment gasket further comprises at least one curved protrusion on its base.
- the present invention minimises load build up when joining gaskets at a corner, i.e. so that the joint has substantially the same load characteristics at the corner as the remainder of the gasket.
- the present invention optionally provides an improved gasket profile whereby one or more curved protrusions on the base of the gasket provide a greater surface area over which a gasket joint can be formed. It has been found that by increasing the surface area of the gasket at the joint, the gasket is less likely to tear or split. Thus, a secure seal for segmentally lined tunnels can be formed whilst using a reduced amount of rubber at the joint.
- the volume of rubber at the joint is minimised to ensure that the gasket can take the strain of the adjoining tunnel segments and avoid the generation of excess force at the joint.
- the profile of the TSG of the present invention provides the required energy within the seal and generates a secure seal when the segments have been assembled; for example against water ingress, or for retention in tunnels used for transport of storage.
- the cross-section of the or each longitudinally extending bore is circular.
- the TSG performs better when a load is applied, i.e. when multiple tunnel segment gaskets are joined.
- the relative movement of the TSG under load will be substantially the same regardless of the direction in which the load is acting on the or each longitudinally extending bore.
- the TSG is better able to withstand the load exerted on it when it collapses into the segment groove in which it is held, when tunnel segments are joined. This ensures that the TSG does not collapse without effectively sealing the segments and minimises the closure forces exerted on the tunnel segments.
- the cross-section of the or each longitudinally extending bore is semi-circular.
- the plurality of longitudinally extending bores comprises one or more, preferably a plurality of bores having a circular cross-section and one or more, preferably a plurality of bores having a semi-circular cross-section.
- the tunnel segment gasket comprises at least two curved protrusions on its base.
- Having two curved protrusions on the base of the TSG provides an increased surface area over which a gasket joint can be formed, whilst ensuring that the gasket is less likely to tear or split.
- the or each curved protrusion is positioned between the two anchoring legs.
- the tunnel segment gasket further comprises at least two shaped transverse protrusions.
- Having shaped transverse protrusions or shoulders allows for secure casting of the TSG in a concrete tunnel segment, wherein the shoulders lay substantially parallel to the plane of the face of the concrete tunnel segment, in use.
- the tunnel segment gasket has a width of between about 20 mm and about 50 mm; preferably, between about 28 mm and about 45 mm.
- the invention provides a method of forming a tunnel segment gasket joint comprising the steps of:
- the method comprises providing a thin elastomeric film between the angled ends of the first and second tunnel segment to form a joint and a strengthening element integral with the joint.
- the method comprises forming a joint and an integral strengthening element wherein the strengthening element is exposed at the base of the gasket.
- the present invention provides a much improved spliced joint for a tunnel segment gasket and also addresses a previously identified problem whereby the diagonal cutting of a profiled TSG was not possible.
- a first and second cutting guide By using a first and second cutting guide, movement of the shaped flexible profile of the TSG away from the cutting blade is prevented to significantly improve the accuracy of the required diagonal cut at the joint-facing ends of the TSG.
- the method of the present invention offers an improvement in ensuring that the angle of the TSG can be carefully selected according to the tunnel segments with which the TSGs will be used and also ensures that the TSG is held securely prior and during cutting.
- Accurate diagonal cutting means that a “spliced” joint can be formed where two TSGs can be secured to each other whilst requiring the addition of only the minimum possible amount of extra elastomeric material at the joint.
- the method of the present invention avoids elastomeric material travelling along the channels of grooves in the gasket.
- the method of the present invention ensures that the load generated at the joint is evenly distributed across the corner; the TSG adjacent thereto and along the reminder of the gasket; that is, no excessive load is created. By carefully maintaining the profile of the TSG this ensures that any point stresses will be avoided, which could lead to splitting of the gasket and crack propagation, so that no cracking of the concrete segments will result over time.
- the elastomeric film is a rubber film.
- the thin elastomeric film has a thickness of between about 0.2 mm and about 2 mm.
- the thin elastomeric or rubber film is provided by placing the film between the angled ends of the first and second tunnel gasket to form a joint; more preferably, the thin elastomeric or rubber film is provided by injecting or “shooting” the elastomeric or rubber film between the angled ends of the first and second tunnel gasket to form a joint; optionally, the thin elastomeric or rubber film is provided by placing a rubber film between the mating faces to be joined.
- the method of forming a tunnel segment gasket joint further comprises the step of clamping at least one end of both the first and second tunnel segment gaskets.
- the invention provides a tunnel segment gasket joint produced by a method described herein.
- the term “about” is interpreted to mean optionally ⁇ 20%, preferably optionally ⁇ 10%, more preferably optionally ⁇ 5%.
- FIG. 1 a is a perspective view of a slice through a tunnel segment gasket constructed in accordance with a first embodiment of the present invention
- FIG. 1 b is a cross-sectional view across the joint, effectively showing half of a tunnel segment gasket, as shown in FIG. 1 a , in accordance with a first embodiment of the present invention
- FIG. 2 is a cross-sectional view of a tunnel segment gasket, as shown in FIG. 1 b , cast in to a concrete tunnel segment;
- FIG. 3 is a cross-sectional view of a tunnel segment gasket constructed in accordance with a second embodiment of the present invention.
- FIG. 4 is a cross-sectional view of a tunnel segment gasket constructed in accordance with a second embodiment of the present invention shown in FIG. 3 , which is shown cast-in to a tunnel segment;
- FIG. 5 is a cross-sectional view of a tunnel segment gasket constructed in accordance with a further embodiment of the present invention.
- FIG. 6 is a cross-sectional view of a tunnel segment gasket constructed in accordance with the further embodiment of the present invention shown in FIG. 5 , which is shown cast-in to a tunnel segment;
- FIG. 7 is a view from above of a cutting guide for cutting a first (left hand) tunnel segment gasket of the present invention to be joined to form a corner joint, as described with respect to FIG. 15 ;
- FIG. 8 is a view from the side of the cutting guide of FIG. 7 , for cutting a first tunnel segment gasket of the present invention to be joined to form a corner joint;
- FIG. 9 is a perspective view of the cutting guide of FIGS. 7 and 8 for cutting a first tunnel segment gasket of the present invention to be joined to form a corner joint;
- FIG. 10 is a view from above of a cutting guide for cutting a second (right hand) tunnel segment gasket of the present invention to be joined to form a corner joint, as described with respect to FIG. 15 ;
- FIG. 11 is a view from the side of the cutting guide of FIG. 10 for cutting a second tunnel segment gasket of the present invention to be joined to form a corner joint;
- FIG. 12 is a perspective view of the cutting guide of FIGS. 10 and 11 for cutting a second tunnel segment gasket of the present invention to be joined to form a corner joint;
- FIG. 13 is a perspective view of the left hand and right hand cutting guides
- FIG. 14 is a schematic view of the cutting of the left hand and right hand tunnel segment gaskets according to the present invention.
- FIG. 15 is a perspective view of a tunnel segment gasket joint having an obtuse angle, in accordance with the present invention.
- FIG. 16 is a view from above of a tunnel segment gasket joint having an obtuse angle
- FIG. 17 is an internal view of the tunnel segment gasket joint of FIG. 16 ;
- FIG. 18 is a perspective view of a tunnel segment joint having an acute angle
- FIG. 19 is a perspective view of a tunnel segment gasket joint having an acute angle, according to the present invention.
- the TSG 1 ′ comprises an elastomeric (rubber) body 3 ′ having a shaped profile.
- the body 3 ′ comprises anchoring legs 5 ′, such that the full profile of the gasket 1 ′, as shown in FIG. 2 comprises two anchoring leg 5 ′, with one on each side of the TSG 1 ′.
- the TSG 1 ′ further comprises a plurality of longitudinally extending bores 7 ′.
- each of the anchoring legs 5 ′ secures the TSG 1 ′ in position when cast in to a concrete tunnel segment 6 ′.
- the gasket 1 ′ is compressed under load of the concrete tunnel segments 6 ′ in which the TSG 1 ′ is cast.
- the width of the gasket 1 ′, excluding the shoulders 13 ′, in a first embodiment is about 28 mm and the height of the main body of the gasket 1 ′, excluding the anchoring legs 5 ′, is about 18 mm.
- the height of each shoulder 13 ′ from the base of the gasket 1 ′ is about 9 mm.
- the width of the base of the gasket is about 21 mm.
- the gasket 1 ′ further comprises a shot film joint 43 ′ and a strengthening element 4 ′ at the base of the gasket 1 ′.
- base of the gasket refers to the face of the gasket 1 ′ between the two anchoring legs 5 ′, which is external to the shot film joint 43 ′.
- the strengthening element 4 ′ is shaped and positioned to increase the strength of the tunnel segment gasket 1 ′ at the joint 43 ′ and reduces the risk of crack propagation when the tunnel segment gaskets 1 ′ are joined and cast in to concrete tunnel segments 6 ′.
- the strengthening element 4 ′ has four sides forming a rhombus shape wherein a centre line of the strengthening element 4 ′ is aligned with the centre line of the shot film joint 43 ′.
- the strengthening element 4 ′ is integrally formed with the shot film joint 43 ′.
- the shot film joint 43 ′ is concealed within the tunnel segment gasket 1 ′ and the strengthening element 4 ′ is concealed, in use by the concrete tunnel segment 6 ′ into which it is cast. It is understood that, in alternative embodiments of the present invention the strengthening element 4 ′ can have a different shape according to user requirements.
- the shape of the strengthening element 4 ′ is determined by the method described with respect to FIGS. 15 and 17 and is formed integrally with the shot film joint 43 ′.
- the tunnel segment gasket (TSG) 1 comprises an elastomeric (rubber) body 3 having a shaped profile.
- the profile comprises two anchoring legs 5 and a plurality of longitudinally extending bores 7 .
- the base 9 of the TSG 1 optionally has two curved protrusions 11 that are arranged to increase the surface area of the base 9 of the TSG 1 .
- the embodiment shown in FIG. 1 has a rubber volume for a 1000 mm length of gasket of 302 cc; however, the volume of rubber is given by way of example only. For any given gasket, the volume of rubber is varied according to the requirements of the given gasket; for example depending on the application for which it is to be used.
- the profile further comprises two shoulders 13 protruding substantially perpendicular to the direction of the anchoring legs 5 .
- the width of the gasket ( FIG. 1 -A), excluding the shoulders 13 , in a first embodiment is about 28 mm and the height of the main body of the gasket ( FIG. 1 -B), excluding the anchoring legs 5 is about 19 mm.
- the height of each shoulder 13 from the base of the gasket ( FIG. 1 -C) is about 8 mm.
- the width of the base of the gasket ( FIG. 1 -D) is about 21 mm.
- the anchoring legs 5 are cast in to a tunnel segment 13 .
- the longitudinally extending bores 7 of the TSG 1 are shown to have a circular cross-section.
- the cross-section of the longitudinally extending bores 7 can be configured according to the anticipated load requirements of the TSG 1 . That is, it is understood that the number, shape and dimensions of each of the longitudinally extending bores 7 can vary according to the gasket's load requirements. Referring to FIG. 2 , when the TSG 1 is cast into the tunnel segment 23 , the volume of the groove 15 in which the TSG 1 sits has a volume of about 335 cc; however, the volume of the groove is given by way of example only.
- the volume of rubber is varied according to the requirements of the given gasket; for example depending on the application for which it is to be used.
- the volume of the rubber and the groove 15 is carefully calculated to ensure that it will be possible to close adjacent tunnel segments 23 securely.
- the shoulders 13 of the TSG 1 are configured to protrude within the tunnel segment in which they are cast, with the shoulders 13 substantially parallel to and along the upper face of the tunnel segment 23 .
- the optional protrusions 11 have a substantially semi-circular profile extending along the base 9 of the TSG 1 .
- the curved profile of the curved protrusions 11 prevents any points of stress when the TSGs are joined; thus, avoiding the risk of splitting of the joint or crack propagation when a load is applied to the joint; that is, when the TSG 1 is used in joining two tunnel segments (not shown).
- the curved profile of the curved protrusions 11 can take the form of an elongate beading running along the length of the underside of the TSG 1 .
- the cross-section of the curved protrusions 11 is semi-circular or domed.
- a plurality of curved protrusions are provided, however, the preferred embodiment is that shown in FIGS. 1 a , 1 b and 2 , as referred to above.
- the surface area of the base 9 of the TSG 1 is increased to allow for efficient joining of two TSGs 1 without an excess of elastomeric material being required at the joint.
- the dimensions of the TSG 1 are altered accordingly.
- the volume of rubber is given by way of example only. For any given gasket, the volume of rubber is varied according to the requirements of the given gasket; for example depending on the application for which it is to be used.
- the width of the gasket 1 ( FIG. 5 -E), excluding the shoulders 13 , in this further embodiment is about 32 mm and the height of the main body of the gasket 1 ( FIG. 5 -F), excluding the anchoring legs 5 is about 20 mm.
- the height of each shoulder 13 from the base of the gasket ( FIG. 5 -G) is about 9 mm.
- the width of the base of the gasket ( FIG. 5 -H) is about 33 mm.
- the width of the base of the gasket is about 40 mm or about 45 mm, but all dimensions will vary according to the sealing requirements and the application of the TSG.
- the profile of the gasket 1 comprises a plurality of longitudinally extending bores 7 having a circular cross-section and also a plurality of longitudinally extending bores 7 b having a substantially semi-circular cross section.
- the profile comprises two anchoring legs 5 and two shoulders 13 protruding substantially perpendicular to the direction of the anchoring legs 5 .
- the anchoring legs 5 are cast in to form a groove 25 in a tunnel segment 23 .
- the shoulders 13 of the TSG 1 are configured to protrude substantially parallel to and along the upper face of the TSG 1 .
- a first cutting guide 30 is used to extrude a first tunnel segment gasket (not shown) along a curing line.
- the cutting guide 30 comprises a bottom plate 32 and a top plate 31 .
- the bottom plate 32 comprises a channel 33 .
- the cross-section of the channel 33 is shaped according to the gasket profile that is required.
- the angle of the channel 33 to the outer faces of the cutting guide is also carefully selected according to the required angle of the joint that is to be formed by the TSG.
- a second cutting guide 35 is used to extrude a first tunnel segment gasket (not shown).
- the cutting guide 35 comprises a bottom plate 37 and a top plate 36 .
- the bottom plate 37 comprises a channel 38 .
- the cross-section of the channel 33 is shaped according to the gasket profile that is required.
- the angle of the channel 38 to the outer faces of the cutting guide is also carefully selected according to the required angle of the joint that is to be formed by the TSG.
- the first and second cutting guides 30 , 35 form the left hand and right hand guides for forming the corner joint of two tunnel segment gaskets 41 , 42 , as shown in FIGS. 15 and 16 .
- a first tunnel segment gasket 41 is extruded through the channel 33 of the left hand cutting guide 30 , shown in FIG. 7 .
- a second tunnel segment gasket 42 is extruded through the channel 38 of the right hand cutting guide 35 .
- two rotating blades 40 a , 40 b are used to accurately cut the end surface of each of the two extruded tunnel segment gaskets 41 , 42 whilst they are held within the respective cutting guides 30 , 35 .
- the present invention also provides a method of manufacturing a tunnel segment gasket joint.
- a first and second tunnel segment gasket 40 , 41 are joined together by shooting in a thin film of rubber 43 , as shown in FIG. 17 .
- the thin film “shot” joint 43 is applied to the first and second tunnel segment gaskets 40 , 41 whilst they are clamped in the required position.
- the increased accuracy of the cutting of the extruded TSGs together with the increased accuracy of the joining is such that the profile of the gasket 40 , 41 is substantially unchanged by the joining method, as shown in FIG. 13 .
- the joining method of the present invention provides a stronger, fully vulcanised joint.
- the optional curved protrusions, at the base of the gasket ensure that not only is the desired angle achieved at the joint but the joint profile is maintained to allow for secure sealing without the risk of split propagation.
- the cutting guides allow for the angle 46 at the joint to be obtuse, as shown in FIG. 16 or to be acute, as shown in FIG. 18 , or to be a 90-degree angle, if required.
- the increased accuracy of the angle at the joint improves the performance of the TSGs when positioned to join tunnel segments. This capability to produce any required joint angle also ensures an accurate fit with the segment with which the TSG is to be used.
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Abstract
A tunnel segment gasket and a method for making and using a tunnel segment gasket (1, 1′) comprising a shaped profile (3, 3′) having at least two anchoring legs (5, 5′) for casting in to a tunnel segment (6, 6′); a plurality of longitudinally extending bores (7, 7′); a shot film joint (43′) and a strengthening element (11, 4′) at the base (9) of the gasket (1, 1′).
Description
- The present invention relates to an improved “cast-in” tunnel gasket and a method of joining such a tunnel gasket.
- Elastomeric (rubber) gaskets are used to seal segmentally formed tunnels; for example, against water ingress. The rubber gaskets are fitted between concrete tunnel segments. Previously, rubber tunnel gaskets were fitted into grooves pre-formed in the tunnel segments and secured with adhesive. However, it has been shown to be advantageous to mould the concrete tunnel segments around a gasket, known as a cast-in tunnel gasket, to form a tunnel segment having an integrated seal.
- An example of an existing cast-in tunnel gasket includes that disclosed in patent publication WO2013189491 (Datwyler), wherein a moulded product is produced in a shutter assembly. It is known to provide such anchored/“cast-in” tunnel seals as an alternative to inserting a seal in a pre-cast groove in the concrete using a contact adhesive. A “cast-in” tunnel segment gasket (TSG) has been found to offer advantages in reliability and eliminates the cost and inconvenience of using adhesives. Currently “cast-in” tunnel segment gaskets are manufactured by encasing the segment gasket in concrete during the casting of the segments themselves. It is also known that it is advantageous to provide a gasket profile that allows for the significant forces that the concrete tunnel segments are to be placed under. For example, the tunnel segment gasket (TSG) comprises profiled geometries according to the expected deformation of the gasket under compression; for example including one or more longitudinal channels running therethrough and/or having “anchored” profiles with legs protruding therefrom. It is known that a cast-in tunnel gasket “collapses” into the groove into which it has formed during use, to close the gap between adjacent concrete tunnel segments.
- However, it has been found that existing cast-in TSG products are problematic, particularly when they are fitted at a corner, i.e. where two gaskets are joined. This is a significant disadvantage of known cast-in TSGs because the gaskets are commonly provided in the form of a frame to be cast-in adjacent to the perimeter of the concrete tunnel segment. Current joining methods for TSGs create problems because of excessive rubber collecting at the join when gaskets are joined by injecting or “shooting” rubber into the corners. This effectively creates a solid corner joint that restricts significantly the movement which is essential to the performance of the gasket as it “collapses” into the groove into which it is fitted. A solid corner join results from “shooting” rubber in at the corner joint, often termed a “shot-joint”, which then travels along the longitudinal channels in the adjoining gaskets. Such a solid, filled corner joint does not allow for any compression or movement of the joint; for example if the TSGs are not aligned perfectly or if there is ground movement after installation. Thus, existing solid corner TSG joints lead to excessive load building up at the corners, which will eventually lead the concrete segments attached thereto to crack. Furthermore, the gaskets will be not be securely held and leaks are very likely to occur.
- This problem has previously been acknowledged with respect to conventional, adhesively fitted gaskets and was solved by allowing for higher arches in the gasket profile at the corners to allow for a more uniform volume of rubber at the joint when compared with the volume of rubber along the length of the gaskets joined thereto. However, the requirements of the profile of a cast-in TSG are quite different from adhesively-held gaskets and the problems associated with excessive rubber at corner joints remain. As previously discussed, the profile of any TSG is configured so that when the solid tunnel segments are joined and bolted together, the relatively “open” profiled of the rubber gasket collapses into the groove in the tunnel segment in which it is held. The cross-section or profile of the gasket is designed to take the strain of the load applied by the adjoining tunnel segments; that is, to minimise the closure forces exerted on the tunnel segments whilst securely sealing the tunnel. Thus, there remains a need for an improved TSG and joining method, which maintains performance of TSG along the full length of the seal, particularly at the corners.
- The present invention sets out to alleviate the problems described above by providing an improved tunnel segment gasket and an improved method of joining tunnel segment gaskets.
- In one aspect, the invention provides a tunnel segment gasket comprising a shaped profile having at least two anchoring legs for casting in to a tunnel segment; a plurality of longitudinally extending bores; a shot film joint and a strengthening element at the base of the gasket.
- It is understood that the “base of the gasket” refers to the face of the gasket between the two anchoring legs, which is external to the shot film joint.
- Preferably, the strengthening element is shaped and positioned to increase the strength of the tunnel segment gasket at the joint.
- Preferably, the strengthening element is a rhombus shape having a centre line parallel to the shot film joint.
- Preferably, the strengthening element is integral with the shot film joint.
- Preferably, the shot film joint is concealed within the tunnel segment gasket and the strengthening element is exposed at the base of the gasket.
- It has been found that the configuration of the present invention provides much improved joint security for tunnel segment gaskets. The strengthening element acts, in use, as a “keying element” and protrudes from the shot film joint at the base of the main body of the shaped profile. When the strengthening element is cast in to a concrete tunnel segment/s the risk of crack propagation is significantly reduced when the gasket is placed under load. The strengthening element of the profile does not affect the load characteristics of the gasket under compression. The strengthening element/“keying element” does not hinder the closure performance of the tunnel segments nor does it affect the load compressing the gasket, but provides a remarkably secure joint. It has been found that the security of the joint is remarkably improved and the risk of the gasket pulling apart at the joint and the joint failing is much reduced.
- Optionally, the tunnel segment gasket further comprises at least one curved protrusion on its base.
- By providing curved protrusion/s on the base of the tunnel segment gasket, the present invention minimises load build up when joining gaskets at a corner, i.e. so that the joint has substantially the same load characteristics at the corner as the remainder of the gasket. The present invention optionally provides an improved gasket profile whereby one or more curved protrusions on the base of the gasket provide a greater surface area over which a gasket joint can be formed. It has been found that by increasing the surface area of the gasket at the joint, the gasket is less likely to tear or split. Thus, a secure seal for segmentally lined tunnels can be formed whilst using a reduced amount of rubber at the joint. The volume of rubber at the joint is minimised to ensure that the gasket can take the strain of the adjoining tunnel segments and avoid the generation of excess force at the joint. The profile of the TSG of the present invention provides the required energy within the seal and generates a secure seal when the segments have been assembled; for example against water ingress, or for retention in tunnels used for transport of storage.
- Preferably, the cross-section of the or each longitudinally extending bore is circular.
- By having cylindrical bores (bores with a circular cross-section) it has been found that the TSG performs better when a load is applied, i.e. when multiple tunnel segment gaskets are joined. The relative movement of the TSG under load will be substantially the same regardless of the direction in which the load is acting on the or each longitudinally extending bore. The TSG is better able to withstand the load exerted on it when it collapses into the segment groove in which it is held, when tunnel segments are joined. This ensures that the TSG does not collapse without effectively sealing the segments and minimises the closure forces exerted on the tunnel segments.
- Optionally, the cross-section of the or each longitudinally extending bore is semi-circular.
- Preferably, the plurality of longitudinally extending bores comprises one or more, preferably a plurality of bores having a circular cross-section and one or more, preferably a plurality of bores having a semi-circular cross-section.
- For TSG having a wider base, to be cast-in to a tunnel segment, it has been found that providing one or more longitudinally extending bores having a semi-circular profile ensures that the gasket performs well when put under strain—i.e. when the tunnel segments are joined and the profile of the gasket collapses into the groove in which it is fitted. The ability of the gasket to collapse ensures that tunnel segments can be safely and securely fitted together without any risk of cracking of the segments or leaks.
- Optionally, the tunnel segment gasket comprises at least two curved protrusions on its base.
- Having two curved protrusions on the base of the TSG provides an increased surface area over which a gasket joint can be formed, whilst ensuring that the gasket is less likely to tear or split.
- Optionally, the or each curved protrusion is positioned between the two anchoring legs.
- Preferably, the tunnel segment gasket further comprises at least two shaped transverse protrusions.
- Having shaped transverse protrusions or shoulders allows for secure casting of the TSG in a concrete tunnel segment, wherein the shoulders lay substantially parallel to the plane of the face of the concrete tunnel segment, in use.
- Optionally, the tunnel segment gasket has a width of between about 20 mm and about 50 mm; preferably, between about 28 mm and about 45 mm.
- In a further aspect, the invention provides a method of forming a tunnel segment gasket joint comprising the steps of:
- i) extruding a first tunnel segment gasket through a first cutting guide;
ii) extruding a second tunnel segment gasket through a second cutting guide;
iii) cutting an angled end of both the first and second tunnel segment gasket;
iv) providing a thin elastomeric film between the angled ends of the first and second tunnel gasket to form a joint. - Preferably, the method comprises providing a thin elastomeric film between the angled ends of the first and second tunnel segment to form a joint and a strengthening element integral with the joint.
- Preferably, the method comprises forming a joint and an integral strengthening element wherein the strengthening element is exposed at the base of the gasket.
- The present invention provides a much improved spliced joint for a tunnel segment gasket and also addresses a previously identified problem whereby the diagonal cutting of a profiled TSG was not possible. By using a first and second cutting guide, movement of the shaped flexible profile of the TSG away from the cutting blade is prevented to significantly improve the accuracy of the required diagonal cut at the joint-facing ends of the TSG. The method of the present invention offers an improvement in ensuring that the angle of the TSG can be carefully selected according to the tunnel segments with which the TSGs will be used and also ensures that the TSG is held securely prior and during cutting. Accurate diagonal cutting means that a “spliced” joint can be formed where two TSGs can be secured to each other whilst requiring the addition of only the minimum possible amount of extra elastomeric material at the joint. The method of the present invention avoids elastomeric material travelling along the channels of grooves in the gasket. The method of the present invention ensures that the load generated at the joint is evenly distributed across the corner; the TSG adjacent thereto and along the reminder of the gasket; that is, no excessive load is created. By carefully maintaining the profile of the TSG this ensures that any point stresses will be avoided, which could lead to splitting of the gasket and crack propagation, so that no cracking of the concrete segments will result over time.
- Preferably, the elastomeric film is a rubber film.
- Preferably, the thin elastomeric film has a thickness of between about 0.2 mm and about 2 mm.
- Preferably, the thin elastomeric or rubber film is provided by placing the film between the angled ends of the first and second tunnel gasket to form a joint; more preferably, the thin elastomeric or rubber film is provided by injecting or “shooting” the elastomeric or rubber film between the angled ends of the first and second tunnel gasket to form a joint; optionally, the thin elastomeric or rubber film is provided by placing a rubber film between the mating faces to be joined.
- Preferably, the method of forming a tunnel segment gasket joint further comprises the step of clamping at least one end of both the first and second tunnel segment gaskets.
- In another aspect, the invention provides a tunnel segment gasket joint produced by a method described herein.
- Within this specification, the term “about” is interpreted to mean optionally ±20%, preferably optionally ±10%, more preferably optionally ±5%.
- For the purposes of clarity and a concise description, features are described herein as part of the same or separate embodiments; however it will be appreciated that the scope of the invention may include embodiments having combinations of all or some of the features described. For example, it will be appreciated that all preferred features described herein are equally applicable to all aspects of the invention described therein.
- The invention will now be described by way of example with reference to the accompanying diagrammatic drawings, in which:—
-
FIG. 1a is a perspective view of a slice through a tunnel segment gasket constructed in accordance with a first embodiment of the present invention; -
FIG. 1b is a cross-sectional view across the joint, effectively showing half of a tunnel segment gasket, as shown inFIG. 1a , in accordance with a first embodiment of the present invention; -
FIG. 2 is a cross-sectional view of a tunnel segment gasket, as shown inFIG. 1b , cast in to a concrete tunnel segment; -
FIG. 3 is a cross-sectional view of a tunnel segment gasket constructed in accordance with a second embodiment of the present invention; -
FIG. 4 is a cross-sectional view of a tunnel segment gasket constructed in accordance with a second embodiment of the present invention shown inFIG. 3 , which is shown cast-in to a tunnel segment; -
FIG. 5 is a cross-sectional view of a tunnel segment gasket constructed in accordance with a further embodiment of the present invention; -
FIG. 6 is a cross-sectional view of a tunnel segment gasket constructed in accordance with the further embodiment of the present invention shown inFIG. 5 , which is shown cast-in to a tunnel segment; -
FIG. 7 is a view from above of a cutting guide for cutting a first (left hand) tunnel segment gasket of the present invention to be joined to form a corner joint, as described with respect toFIG. 15 ; -
FIG. 8 is a view from the side of the cutting guide ofFIG. 7 , for cutting a first tunnel segment gasket of the present invention to be joined to form a corner joint; -
FIG. 9 is a perspective view of the cutting guide ofFIGS. 7 and 8 for cutting a first tunnel segment gasket of the present invention to be joined to form a corner joint; -
FIG. 10 is a view from above of a cutting guide for cutting a second (right hand) tunnel segment gasket of the present invention to be joined to form a corner joint, as described with respect toFIG. 15 ; -
FIG. 11 is a view from the side of the cutting guide ofFIG. 10 for cutting a second tunnel segment gasket of the present invention to be joined to form a corner joint; -
FIG. 12 is a perspective view of the cutting guide ofFIGS. 10 and 11 for cutting a second tunnel segment gasket of the present invention to be joined to form a corner joint; -
FIG. 13 is a perspective view of the left hand and right hand cutting guides; -
FIG. 14 is a schematic view of the cutting of the left hand and right hand tunnel segment gaskets according to the present invention; -
FIG. 15 is a perspective view of a tunnel segment gasket joint having an obtuse angle, in accordance with the present invention; -
FIG. 16 is a view from above of a tunnel segment gasket joint having an obtuse angle; -
FIG. 17 is an internal view of the tunnel segment gasket joint ofFIG. 16 ; -
FIG. 18 is a perspective view of a tunnel segment joint having an acute angle; and -
FIG. 19 is a perspective view of a tunnel segment gasket joint having an acute angle, according to the present invention. - Referring to
FIG. 1a andFIG. 1b , showing a slice through the tunnel segment gasket (TSG) 1′, theTSG 1′ comprises an elastomeric (rubber)body 3′ having a shaped profile. Thebody 3′ comprises anchoringlegs 5′, such that the full profile of thegasket 1′, as shown inFIG. 2 comprises two anchoringleg 5′, with one on each side of theTSG 1′. TheTSG 1′ further comprises a plurality of longitudinally extendingbores 7′. - Referring to
FIG. 2 , each of the anchoringlegs 5′ secures theTSG 1′ in position when cast in to aconcrete tunnel segment 6′. In use, thegasket 1′ is compressed under load of theconcrete tunnel segments 6′ in which theTSG 1′ is cast. The width of thegasket 1′, excluding theshoulders 13′, in a first embodiment is about 28 mm and the height of the main body of thegasket 1′, excluding the anchoringlegs 5′, is about 18 mm. The height of eachshoulder 13′ from the base of thegasket 1′ is about 9 mm. The width of the base of the gasket is about 21 mm. - Referring to
FIG. 1b , thegasket 1′ further comprises a shot film joint 43′ and a strengtheningelement 4′ at the base of thegasket 1′. It is understood that the “base of the gasket” refers to the face of thegasket 1′ between the two anchoringlegs 5′, which is external to the shot film joint 43′. The strengtheningelement 4′ is shaped and positioned to increase the strength of thetunnel segment gasket 1′ at the joint 43′ and reduces the risk of crack propagation when thetunnel segment gaskets 1′ are joined and cast in to concretetunnel segments 6′. - In the embodiment of
FIG. 1b , the strengtheningelement 4′ has four sides forming a rhombus shape wherein a centre line of the strengtheningelement 4′ is aligned with the centre line of the shot film joint 43′. The strengtheningelement 4′ is integrally formed with the shot film joint 43′. The shot film joint 43′ is concealed within thetunnel segment gasket 1′ and the strengtheningelement 4′ is concealed, in use by theconcrete tunnel segment 6′ into which it is cast. It is understood that, in alternative embodiments of the present invention the strengtheningelement 4′ can have a different shape according to user requirements. The shape of the strengtheningelement 4′ is determined by the method described with respect toFIGS. 15 and 17 and is formed integrally with the shot film joint 43′. - Referring to
FIG. 3 , the tunnel segment gasket (TSG) 1 comprises an elastomeric (rubber)body 3 having a shaped profile. The profile comprises two anchoringlegs 5 and a plurality of longitudinally extendingbores 7. Thebase 9 of theTSG 1 optionally has twocurved protrusions 11 that are arranged to increase the surface area of thebase 9 of theTSG 1. The embodiment shown inFIG. 1 has a rubber volume for a 1000 mm length of gasket of 302 cc; however, the volume of rubber is given by way of example only. For any given gasket, the volume of rubber is varied according to the requirements of the given gasket; for example depending on the application for which it is to be used. The profile further comprises twoshoulders 13 protruding substantially perpendicular to the direction of the anchoringlegs 5. The width of the gasket (FIG. 1 -A), excluding theshoulders 13, in a first embodiment is about 28 mm and the height of the main body of the gasket (FIG. 1 -B), excluding the anchoringlegs 5 is about 19 mm. The height of eachshoulder 13 from the base of the gasket (FIG. 1 -C) is about 8 mm. The width of the base of the gasket (FIG. 1 -D) is about 21 mm. - In use, as shown in
FIG. 4 , the anchoringlegs 5 are cast in to atunnel segment 13. Thelongitudinally extending bores 7 of theTSG 1 are shown to have a circular cross-section. However, in alternative embodiments the cross-section of thelongitudinally extending bores 7 can be configured according to the anticipated load requirements of theTSG 1. That is, it is understood that the number, shape and dimensions of each of thelongitudinally extending bores 7 can vary according to the gasket's load requirements. Referring toFIG. 2 , when theTSG 1 is cast into thetunnel segment 23, the volume of thegroove 15 in which theTSG 1 sits has a volume of about 335 cc; however, the volume of the groove is given by way of example only. For any given gasket, the volume of rubber is varied according to the requirements of the given gasket; for example depending on the application for which it is to be used. The volume of the rubber and thegroove 15 is carefully calculated to ensure that it will be possible to closeadjacent tunnel segments 23 securely. Theshoulders 13 of theTSG 1 are configured to protrude within the tunnel segment in which they are cast, with theshoulders 13 substantially parallel to and along the upper face of thetunnel segment 23. - In the embodiments shown in
FIG. 3 (andFIG. 4 ), theoptional protrusions 11 have a substantially semi-circular profile extending along thebase 9 of theTSG 1. The curved profile of thecurved protrusions 11 prevents any points of stress when the TSGs are joined; thus, avoiding the risk of splitting of the joint or crack propagation when a load is applied to the joint; that is, when theTSG 1 is used in joining two tunnel segments (not shown). It is envisaged that the curved profile of thecurved protrusions 11 can take the form of an elongate beading running along the length of the underside of theTSG 1. The cross-section of thecurved protrusions 11 is semi-circular or domed. It is also envisaged that it alternative embodiments, a plurality of curved protrusions are provided, however, the preferred embodiment is that shown inFIGS. 1a, 1b and 2, as referred to above. By providing the optionalcurved protrusions 11, the surface area of thebase 9 of theTSG 1 is increased to allow for efficient joining of twoTSGs 1 without an excess of elastomeric material being required at the joint. - As shown in
FIG. 5 andFIG. 6 , in a further embodiment of the present invention, when theTSG 1 is to be cast in to atunnel segment 23, havinggroove volume 25 of about 434 cc for a 1000 mm length, the dimensions of theTSG 1 are altered accordingly. The volume of rubber is given by way of example only. For any given gasket, the volume of rubber is varied according to the requirements of the given gasket; for example depending on the application for which it is to be used. - The width of the gasket 1 (
FIG. 5 -E), excluding theshoulders 13, in this further embodiment is about 32 mm and the height of the main body of the gasket 1 (FIG. 5 -F), excluding the anchoringlegs 5 is about 20 mm. The height of eachshoulder 13 from the base of the gasket (FIG. 5 -G) is about 9 mm. The width of the base of the gasket (FIG. 5 -H) is about 33 mm. In alternative embodiments, the width of the base of the gasket is about 40 mm or about 45 mm, but all dimensions will vary according to the sealing requirements and the application of the TSG. - As shown in
FIG. 5 , for the further embodiment shown, the profile of thegasket 1 comprises a plurality of longitudinally extendingbores 7 having a circular cross-section and also a plurality of longitudinally extendingbores 7 b having a substantially semi-circular cross section. The profile comprises two anchoringlegs 5 and twoshoulders 13 protruding substantially perpendicular to the direction of the anchoringlegs 5. - As shown in
FIG. 6 , in use, the anchoringlegs 5 are cast in to form agroove 25 in atunnel segment 23. Theshoulders 13 of theTSG 1 are configured to protrude substantially parallel to and along the upper face of theTSG 1. - As shown in
FIGS. 7, 8 and 9 , afirst cutting guide 30 is used to extrude a first tunnel segment gasket (not shown) along a curing line. As shown inFIG. 9 , the cuttingguide 30 comprises abottom plate 32 and atop plate 31. Thebottom plate 32 comprises achannel 33. As shown inFIG. 8 , the cross-section of thechannel 33 is shaped according to the gasket profile that is required. The angle of thechannel 33 to the outer faces of the cutting guide is also carefully selected according to the required angle of the joint that is to be formed by the TSG. - As shown in
FIGS. 10, 11 and 12 , asecond cutting guide 35 is used to extrude a first tunnel segment gasket (not shown). As shown inFIG. 10 , the cuttingguide 35 comprises abottom plate 37 and atop plate 36. Thebottom plate 37 comprises achannel 38. As shown inFIG. 9 , the cross-section of thechannel 33 is shaped according to the gasket profile that is required. The angle of thechannel 38 to the outer faces of the cutting guide is also carefully selected according to the required angle of the joint that is to be formed by the TSG. - Referring to
FIG. 13 , the first and second cutting guides 30, 35 form the left hand and right hand guides for forming the corner joint of twotunnel segment gaskets FIGS. 15 and 16 . To form the corner joint a firsttunnel segment gasket 41 is extruded through thechannel 33 of the lefthand cutting guide 30, shown inFIG. 7 . A secondtunnel segment gasket 42 is extruded through thechannel 38 of the righthand cutting guide 35. - Referring to
FIG. 14 , tworotating blades tunnel segment gaskets - Referring to
FIG. 15 , the present invention also provides a method of manufacturing a tunnel segment gasket joint. A first and secondtunnel segment gasket rubber 43, as shown inFIG. 17 . The thin film “shot” joint 43 is applied to the first and secondtunnel segment gaskets gasket FIG. 13 . The joining method of the present invention provides a stronger, fully vulcanised joint. The optional curved protrusions, at the base of the gasket ensure that not only is the desired angle achieved at the joint but the joint profile is maintained to allow for secure sealing without the risk of split propagation. - Referring to
FIG. 16 , the cutting guides allow for theangle 46 at the joint to be obtuse, as shown inFIG. 16 or to be acute, as shown inFIG. 18 , or to be a 90-degree angle, if required. The increased accuracy of the angle at the joint improves the performance of the TSGs when positioned to join tunnel segments. This capability to produce any required joint angle also ensures an accurate fit with the segment with which the TSG is to be used. - The above described embodiment has been given by way of example only, and the skilled reader will naturally appreciate that many variations could be made thereto without departing from the scope of the claims.
Claims (16)
1. A tunnel segment gasket comprising:
a shaped profile having at least two anchoring legs for casting in to a tunnel segment;
a plurality of longitudinally extending bores;
a shot film joint (43′) and a strengthening element at a base of the tunnel segment gasket.
2. The tunnel segment gasket according to claim 1 , wherein the strengthening element is a rhombus shape having a centre line parallel to the shot film joint.
3. The tunnel segment gasket according to claim 1 , wherein the strengthening element is integral with the shot film joint.
4. The tunnel segment gasket according to claim 3 , wherein the shot film joint is concealed within the tunnel segment gasket and the strengthening element is exposed at the base of the tunnel segment gasket.
5. The tunnel segment gasket according to claim 1 , wherein the cross-sections of the plurality of longitudinally extending bores are circular or semi-circular.
6. The tunnel segment gasket according to claim 1 , wherein the tunnel segment gasket comprises at least two curved protrusions on the base of the tunnel segment gasket.
7. The tunnel segment gasket according to claim 6 , wherein the at least two curved protrusion are positioned between the two anchoring legs.
8. The tunnel segment gasket according to claim 1 , wherein the tunnel segment gasket further comprises at least two shaped transverse protrusions.
9. A method of forming a tunnel segment gasket joint comprising:
extruding a first tunnel segment gasket through a first cutting guide;
extruding a second tunnel segment gasket through a second cutting guide;
cutting an angled end of both the first and second tunnel segment gaskets;
providing a thin elastomeric film between the angled ends of the first and second tunnel segment gaskets to form a joint.
10. The method according to claim 9 , further comprising providing a strengthening element integral with the joint.
11. The method according to claim 9 , further comprising providing an integral strengthening element wherein the integral strengthening element is exposed at the base of the first tunnel segment gasket.
12. The method according to claim 9 , wherein the thin elastomeric film is a rubber film.
13. The method according to claim 9 , wherein the thin elastomeric film has a thickness of between about 0.2 mm and about 2 mm.
14. The method according to claim 12 , wherein the thin elastomeric or rubber film is provided by injecting the thin elastomeric or rubber film between the angled ends of the first and second tunnel segment gaskets to form a joint.
15. The method according to claim 9 , further comprising: clamping at least one end of both the first and second tunnel segment gaskets.
16. A tunnel segment gasket joint produced by a method comprising:
extruding a first tunnel segment gasket through a first cutting guide;
extruding a second tunnel segment gasket through a second cutting guide;
cutting an angled end of both the first and second tunnel segment gaskets;
providing a thin elastomeric film between the angled ends of the first and second tunnel segment gaskets to form a joint, wherein the thin elastomeric film is a rubber film that has a thickness of between about 0.2 mm and about 2 mm provided by injecting the thin elastomeric or rubber film between the angled ends of the first and second tunnel segment gaskets to form a joint;
providing a strengthening element integral with the joint, wherein the integral strengthening element is exposed at the base of the first tunnel segment gasket; and
clamping at least one end of both the first and second tunnel segment gaskets.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB1601753.5A GB201601753D0 (en) | 2016-02-01 | 2016-02-01 | Cast-in tunnel gasket and joining method |
GB1601753.5 | 2016-02-01 | ||
GB1611217.9 | 2016-06-28 | ||
GB1611217.9A GB2541978B (en) | 2016-02-01 | 2016-06-28 | Cast-in tunnel gasket and joining method |
GB2017134420 | 2017-01-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20210215042A1 true US20210215042A1 (en) | 2021-07-15 |
Family
ID=76761035
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/074,046 Abandoned US20210215042A1 (en) | 2016-02-01 | 2017-01-30 | Cast-in tunnel gasket and joining method |
Country Status (1)
Country | Link |
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US (1) | US20210215042A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN116141535A (en) * | 2023-02-21 | 2023-05-23 | 绵阳锐洋新材料技术开发有限公司 | Pretreatment equipment and method for recycling waste rubber strips |
-
2017
- 2017-01-30 US US16/074,046 patent/US20210215042A1/en not_active Abandoned
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN116141535A (en) * | 2023-02-21 | 2023-05-23 | 绵阳锐洋新材料技术开发有限公司 | Pretreatment equipment and method for recycling waste rubber strips |
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