WO1998016721A1

WO1998016721A1 - Resin-coated segment, and manufacture thereof

Info

Publication number: WO1998016721A1
Application number: PCT/JP1997/003708
Authority: WO
Inventors: Masatsugu Yamamoto; Masayoshi Nakagawa; Hiroki Someya; Tadashi Tanaka; Yutaka Fujino; Akira Kase; Kazuo Matsumoto; Kiyoshi Takahashi; Akira Nishikata; Manabu Kondo; Noriyuki Shima; Hirofumi Okuno; Yuichi Masuda
Original assignee: C. I. Kasei Co., Ltd.
Priority date: 1996-10-15
Filing date: 1997-10-15
Publication date: 1998-04-23
Also published as: AU4571997A

Abstract

A method of manufacturing a resin-coated segment (71) having a simple construction and superior water-tightness, and a segment manufactured by this method. Resin coating material (11) covers at least one of the surfaces of the segment which forms the interior or exterior surface of a shield tunnel. This resin coating material (11) is integrally formed with anchor pins (17) or plates (18) while the pins or plates are embedded in the surface of the material to come into contact with concrete (74). The resin-coated segment (11) is manufactured by filling concrete into a segment mold after the resin coating material, reinforcing bars, and couplings have been set in the segment mold. The resin coating material (11) is formed from liquid reaction-injection molding material principally composed of norbornene-based monomer consisting of, e.g., dicyclopentadiene, and a metathesis catalyst. Accordingly, large resin coating material integrally formed with anchor members (17, 18, 19) can be readily manufactured.

Description

DESCRIPTION RESIN-COATED SEGMENT, AND MANUFACTURE THEREOF

BACKGROUND OF THE INVENTION Field of the Invention:

The present invention relates to a resin-coated segment used for constructing a highly-watertight shield tunnel by assembling a plurality of resin-coated segments, and to a method of manufacturing the segment.

Particularly, the present invention relates to a method of manufacturing a resin-coated segment used for constructing shield tunnels for use as railways or freeways; tunnels requiring water-tightness such as tunnels for drains, sewers, or underground multipurpose pits; watertight constructions having a substantially circular shape, a semi-circular shape, or a polygonal shape; or multiple-geometry constructions comprised of these constructions in combination; and also relates to the resin-coated segment manufactured by the method. Description of the Prior Art:

Fig. 22 is a schematic representation of a shield tunnel which employs existing segments. Figs. 23A and 23B are fragmentary views showing the profile of each of the segments shown in Fig. 22.

As shown in Figs. 22 and Figs. 23A, 23B, the shield tunnel is made up of eight segments 25111, 25112, and 25113. The end face on each side of the type A segment 25111 shown in Fig. 23A is set so as to be aligned with the line which passes through the center of the longitudinal axis of the shield tunnel at right angles when the segments are circularly assembled into a shield tunnel.

The type B segment 25112 shown in Fig. 23B is brought into contact at one end with the type A segment 25111 and has at the other end a tapered portion 25112'.

The type K segment 25113 shown in Fig. 23C has at both ends tapered portions 25113' so as to be able to come into contact at both ends with the tapered portions 25112' of the type B segment 25112.

First, as shown in Fig. 22, the reinforced concrete segments 25111 are stacked in order from the lowermost portion into a ring shape, and the thus-stacked segments are joined to each other in a circumferential direction by means of bolts and nuts. Finally, the type K segment 25113 is fitted into the space between the tapered portions 25112' of the type B segments 25112 from below, and they are joined together by means of the bolts and nuts, whereby joint planes 25114 and 25115 are formed. A ring is now completed.

A shield tunnel is constructed by connecting a required number of thus-formed rings in the axial direction (or in the longitudinal direction of the tunnel) . In a shield tunnel for use as a sewer, waste water is apt to cause hydrogen sulfide gas. This gas turns into an acid, such as sulfurous acid, by reaction with water, and the thus-produced acid deteriorates concrete included in the segment or corrodes the bolts or nuts .

To prevent these problems, the interior of the shield tunnel is reinforced with secondary lining concrete, and the interior surface of the secondary lining concrete is coated with epoxy resin.

In the segment which covers the interior surface of the shield tunnel with resin, the resin may be used as a part of a mold of concrete. However, if great thrust is exerted on the shield tunnel, the adhesion of the resin to the concrete is deteriorated, thereby posing a problem with regard to strength.

More specifically, even in a case where the resin and the concrete each have strength for materials, if there is a clearance between the resin and the concrete, the strength of the box-shaped segment drops .

In a resin-coated segment whose three or five surfaces are coated with a resin coating member, since a thermoplastic resin portion is formed into a box shape, metal molds for injection molding purposes become bulky and costly.

Particularly, in order to prevent the entry of water from outside, the interior surface of a segment to be used in a shield tunnel is coated with, e.g., thermosetting resin-based composite material (FRP) reinforced with glass fibers; paint made of polyvinyl chloride, urethane resin, or epoxy resin; or a resin member, at the time of application of secondary lining concrete on a building site. Such a method of coating the tunnel with paint or a resin member requires a period for additional works after the construction of the tunnel has been finished, thereby adding to the cost.

German Patent Publication GB2099479 describes a concrete segment whose interior and side surfaces are coated with coating material made of polyvinyl chloride. In order to improve the adhesion of the coating material to concrete, the coating material is provided with protuberances having an anchor rib construction. Since such a coating material having an anchor rib construction is manufactured by extrusion molding, it is difficult to manufacture a wide coating material. After the extrusion molding of the coating material, there are further needed steps of machining the material in a cross direction by welding and of welding side members to the coating material. As described above, it requires a lot of expense in time and effort to manufacture the coating material, thereby posing a problem with respect to productivity. SUMMARY OF THE INVENTION

Accordingly, the present invention has been contrived to solve the problems in the prior art, and the object of the present invention is to provide a method of manufacturing a resin-coated segment which has a simple construction and superior water-tightness and is capable of maintaining the compressive strength of a shield tunnel by improving the adhesion of a mold to concrete, and also to provide the resin-coated segment manufactured by the method.

Another object of the present invention is to provide a method of manufacturing a segment which has a resin-coated interior surface and employs inexpensive molds.

Still another object of the present invention is to provide a segment that has a resin-coated interior surface and can be thinned by forming a bolt box into a compact shape which permits the use of curved bolts .

A further object of the present invention is to provide a segment which has a compact bolt box and is suitable for use in a shield tunnel to be used as a sewer, and a tunnel constructed from the segments .

A still further object of the present invention is to provide a segment which has a resin-coated interior surface and forms bolt boxes and a grout inlet integrally with the interior surface of a tunnel to thereby realize the improved water-tightness of the tunnel, the standardization of closures for use with the boxes and inlet, and reduction in labor for the construction of the tunnel. An additional object of the present invention is to provide a method of manufacturing a segment which has a resin-coated exterior surface; which is used in a shield tunnel having a resin-coated outer surface; and which requires inexpensive molds at the time of molding of the segment; and also to provide the segment manufactured by the method.

A still additional object of the present invention is to provide a method of manufacturing a segment which has a resin-coated interior or exterior surface and enables cost reduction by use of a pre-molded segment main body also as a mold, and the segment manufactured by the method.

DISCLOSURE OF THE INVENTION

In accordance with a first aspect of the invention, a resin-coated segment is made up of a segment main body which is composed of a reinforced concrete segment, a steel segment, a ductile segment, or a composite segment composed of combinations thereof; resin coating material which covers at least either an interior or exterior surface of a shield tunnel or a construction; and anchor members embedded in the segment main body and the resin coating material.

A shield tunnel or construction having high water-tightness is constructed by joining the axial or circumferential joint surfaces of the resin-coated segments together. Anchor members, e.g., anchor pins or plates, are provided in the mold used for manufacturing the resin coating material in such a way that the anchor members are embedded in the bottom of the coating material which covers one of the surfaces of the segment so as to be embedded in both the segment main body and the resin coating material.

Accordingly, the resin-coated segment does not cause the separation of the segment main body from the resin coating material and can possess strength as designed.

In accordance with a second aspect of this invention, the resin coating material is made of hardening resin and includes a bottom plate for covering one of the surfaces of the segment which serves as either the interior or exterior surface of the shield tunnel. The hardening resin contracts when setting, thereby bringing the segment main body in close contact with the anchor members. Accordingly, the resin coating material is prevented from being separated from the segment main body.

In accordance with a third aspect of this invention, the resin coating material is made of hardening resin and includes two joint walls which serve as joint surfaces perpendicular to the axial direction of the shield tunnel and a bottom plate for covering one of the surfaces of the segment which serves either the interior or exterior surface of the shield tunnel. Accordingly, since the three surfaces of the segment are coated with the resin coating material, the water-tightness of the shield tunnel or construction is improved.

In accordance with a fourth aspect of this invention, the resin coating material is made of hardening resin and includes all joint walls which serve as joint surfaces used for joining segments together and a bottom plate for covering one of the surfaces of the segment which serves either the interior or exterior surface of the shield tunnel. Since all the joint surfaces of the resin-coated segment are coated with the resin coating material, the joint surfaces between the segments are prevented from being corroded. Accordingly, the durability of the segments are improved.

In accordance with a fifth aspect of this invention, the bottom plate of the resin coating material may be formed into a trapezoidal, rectangular, or hexagonal shape, i.e., a polygonal shape. The bottom plate of the resin coating material has a plane or circular-arc surface. The resin coating material can be arbitrarily selected in accordance with the geometry of a shield tunnel or construction.

In accordance with a sixth aspect of this invention, the joint walls of the resin coating material have anchor ribs . The anchor ribs formed on the joint walls of the resin coating material are tapered so as to have a smaller thickness or size from the bottom to the top, thereby enabling ready removal of the resin coating material from the mold.

In accordance with a seventh aspect of this invention, the sufficient height of the joint walls of the resin coating material is 80% or less of the thickness of the resin-coated segment in terms of study results regarding expenses of the mold and water-tightness .

In accordance with an eighth aspect of this invention, the anchor members provided in the bottom plate of the resin coating material are at least either anchor pins or plates . These anchor members are formed into a shape which makes it easy for the anchor members to adhere to the resin coating material and the segment and to be easily removed from the mold. These anchor members are provided in the bottom as individual members .

In accordance with a ninth aspect of this invention, the hardening resin which forms the resin coating material is formed from reaction-injection molding material principally composed of norbornene-based monomer consisting of, e.g., dicyclopentadiene, and a metathesis catalyst. The reaction injection molding material has a low degree of viscosity and can be subjected to reaction injection mold at low pressure. Therefore, inexpensive molds can be used for this molding material . In accordance with a tenth aspect of this invention, the hardening resin which forms the resin coating material is formed from fiber-reinforced plastics composed of a sheet molding compound principally including unsaturated polyester resin. The fiber-reinforced plastics can sufficiently bear the strength exerted by a shield tunnel or construction which employs the plastics, according to its objective and size.

In accordance with an eleventh aspect of this invention, the segment main body is composed of a reinforced concrete segment, a steel segment, a ductile segment, or a composite segment composed of combinations thereof. The material of the segment main body is selected from various materials according to the objective or size of the shield tunnel .

In accordance with a twelfth aspect of this invention, a method of manufacturing a resin-coated segment is directed to resin-coated segments of reinforced concrete.

Liquid hardening resin is poured into a coating material mold having anchor members provided therein, and resin coating material is formed by reaction-injection molding. At the time of the reaction injection molding, part of anchor members are integrally embedded in the bottom plate of the resin coating material which covers the interior or exterior surface of the resin-coated segment. The liquid hardening resin is formed from reaction-injection molding material principally composed of norbornene-based monomer consisting of, e.g., dicyclopentadiene, and a metathesis catalyst.

The reaction injection molding material has a low degree of viscosity and can be subjected to reaction injection mold at low pressure. Therefore, large resin coating material integrally formed with the anchor members can be readily manufactured .

Further, after the resin coating material has been set in a segment mold, reinforcing bars and couplings are placed in the mold. Subsequently, concrete is filled into the segment mold.

Since the resin coating material is set in the segment mold, only a small amount of release agent is needed for separation of the concrete from the segment mold. Accordingly, the separation of the concrete from the mold becomes easy.

In accordance with a thirteenth aspect of this invention, a method of manufacturing a resin-coated segment is directed to resin-coated segments of reinforced concrete.

Liquid hardening resin is poured into a coating material mold having anchor members provided therein, and resin coating material is formed by reaction-injection molding. At the time of the reaction injection molding, resin coating material is formed to have at least two joint walls (more preferably all the joint walls) and one bottom plate for covering either the interior or exterior surface of the resin-coated segment, and part of anchor members are integrally embedded in the bottom plate of the resin coating material which covers the interior or exterior surface of the resin-coated segment. The liquid hardening resin is formed from reaction-injection molding material principally composed of norbornene-based monomer consisting of e.g., dicyclopentadiene, and a metathesis catalyst.

After the resin coating material has been set in a segment mold, reinforcing bars and couplings are placed in the mold. Subsequently, retaining spacers are fitted on reinforcing steel in close proximity to the joint walls. While the segment mold is pressed against the joint walls by means of the retaining spacers, concrete is filled into the segment mold, and the segment mold is vibrated so as to compact the thus-filled concrete.

In accordance with a fourteenth aspect of this invention, reaction-injection molding material principally composed of norbornene-based monomer consisting of, e.g., dicyclopentadiene, and a metathesis catalyst is used for the reaction injection mold, whereby resin coating material is formed. The reaction injection molding material has a low degree of viscosity and can be subjected to reaction injection mold at low pressure. Therefore, large resin coating material integrally formed with the anchor members can be readily manufactured .

In accordance with a fifteenth aspect of this invention, a method of manufacturing a resin-coated segment is directed to resin-coated segments of reinforced concrete.

A sheet molding compound is set in a coating material mold having anchor members provided therein and is thermally cured by pressing, so that resin coating material is formed in such a way that part of the anchor members are integrally embedded in the bottom plate which covers the interior or exterior surface of the resin-coated segment.

After the resin coating material has been set in a segment mold, reinforcing bars and couplings are placed in the mold. Subsequently, for example, concrete is filled into the segment mold.

The resin coating material formed by thermally curing the sheet molding compound is inexpensive and can provide sufficient strength according to its use.

In accordance with a sixteenth aspect of this invention, a method of manufacturing a resin-coated segment is directed to resin-coated segments of reinforced concrete. A sheet molding compound is set in a coating material mold having anchor members provided therein and is thermally cured by pressing, so that resin coating material is formed in such a way that part of the anchor members are integrally embedded in the bottom plate which covers the interior or exterior surface of the resin-coated segment.

The resin coating material is formed to have at least two joint walls and one bottom plate for covering either the interior or exterior surface of the resin-coated segment, and part of anchor members are integrally embedded in the bottom plate of the resin coating material.

The resin coating material is set in a segment mold. Reinforcing steel and couplings are placed in the segment mold, and retaining spacers are fitted on the reinforcing steel in close proximity to the joint walls.

While the segment mold is pressed against the joint walls by means of the retaining spacers, concrete is filled into the segment mold, and the segment mold is vibrated so as to compact the thus-filled concrete.

In accordance with a seventeenth aspect of the invention, a method of manufacturing a resin-coated segment is directed to a method of coating the surface of various types of segments which includes an exterior surface with resin by reaction injection molding liquid hardening resin applied to the surface.

In a first step, a segment main body which has anchor members and/or recessed formed on the exterior surface thereof is manufactured. Various types of elements can be used as the anchor members. For example, rivets may be welded to the surface of a steel segment.

In a second step, there is positioned a mold for molding coating material of hardening resin so as to cover the exterior surface and joint walls of the segment main body formed in the first step.

In a third step, the resin coating material is made from hardening resin principally composed of norbornene-based monomer consisting of, e.g., dicyclopentadiene, and a metathesis catalyst within the mold by reaction-injection molding.

In a fourth step, a resin-coated segment is removed from the mold after the coating material has set. In accordance with an eighteenth aspect of the invention, a method of manufacturing a resin-coated segment is directed to a method of coating the surface of various types of segments which includes an exterior surface with resin by reaction injection molding liquid hardening resin applied to the surface.

In a first step, a segment main body which has anchor members formed on the interior surface thereof is manufactured.

In a second step, there is positioned a mold for molding coating material of hardening resin so as to cover the interior surface and joint walls of the segment main body.

In a fourth step, a resin-coated segment is removed from the mold after the coating material has set.

In accordance with a nineteenth aspect of this invention, the segment main body is subjected to reaction injection molding after having been heated to an arbitrary temperature in advance. If the concrete of the segment main body has been heated in advance, the reaction injection molding becomes easy to perform. In accordance with a twentieth aspect of this invention, the segment main body is subjected to reaction injection molding after resin, e.g., olefin-based resin, has been applied to the main body in advance.

Since the reaction injection molding material has good adhesion with respect to the olefin-based resin, and hence the resin is prevented from being separated from the molding material .

In accordance with a twenty first aspect of this invention, the segment main body may be a reinforced concrete segment, a steel segment, a ductile segment, or a composite segment composed of combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1A is a top view of a trapezoidal mold for use with a trapezoidal resin-coated segment in accordance with one embodiment of the present invention;

Fig. IB is a cross-sectional view taken across line X-X' shown in Fig. 1A;

Fig. IC is a cross-sectional view taken across line Y-Y' shown in Fig. 1A;

Fig. 2 is a cross-sectional view taken across line Z-Z' shown in Fig. 1A;

Fig. 3A is a cross-sectional view showing a lower portion of an anchor rib shown in Fig. 2; Fig. 3B is a cross-sectional view showing an upper portion of the anchor rib shown in Fig. 2;

Figs . 4A through 4D are descriptive illustrations for describing different examples of anchor pins in accordance with one embodiment ;

Figs . 5A and 5B are schematic representations for describing a joint between the trapezoidal resin-coated segments;

Fig. 6 is a diagrammatic representation showing the tunnel constructed by assembly of the trapezoidal resin-coated segments in accordance with the present embodiment;

Fig. 7A is a view showing a segment in accordance with another embodiment of this invention, in which the concrete becomes exposed inside the shield tunnel;

Fig. 7B is a view showing a segment in accordance with another embodiment of the invention, in which the resin coating material becomes exposed;

Fig. 8 is a schematic representation for describing a hexagonal resin-coated segment in accordance with still another embodiment of this invention.

Fig. 9 is a schematic representation for describing a rectangular resin-coated segment in accordance with yet another embodiment of this invention;

Fig. 10 is a schematic representation for describing the joint between the segments shown in Fig. 9; Fig. 11 is a schematic representation for describing coupling means, in accordance with a further embodiment, which joins the reins-coated segments together through use of bolts and nuts ;

Fig. 12 is a schematic representation for describing coupling means, in accordance with a still further embodiment of the invention, which joins the resin-coated segments together by means of through bolts;

Fig. 13 is a schematic representation for describing joining means, in accordance with a yet further embodiment of this invention, which joins the resin-coated segments together through use of curved bolts;

Figs. 14A and 14B are schematic representations for describing joining means, in accordance with an additional embodiment of this invention, which joins the resin-coated segments together through use of tapered hardware;

Fig. 15 is a schematic representation for describing joining means, in accordance with still another embodiment of this invention, which joins the resin-coated segments together through use of diagonal bolts;

Fig. 16 is a schematic representation for describing joining means, in accordance with yet another embodiment of this invention, which joins the resin-coated segments together through use of knuckle pins; Fig. 17A is a schematic representation for describing a shield tunnel in accordance with a furthermore embodiment of this invention, in which the tunnel is constructed by joining together, in the circumferential and axial directions of the tunnel, substantially-trapezoidal resin-coated segments of varying sizes whose both sides are graded at a given angle with respect to the axial direction of the tunnel;

Fig. 17B is an exploded view showing the substantially-trapezoidal resin-coated segments joined in the circumferential direction of the shield tunnel;

Fig. 17C is a diagrammatic representation for describing a curved shield tunnel constructed by joining together the substantially-trapezoidal resin-coated segments in such a way that the shorter sides and the longer sides of the segments are respectively connected to each other;

Fig. 18 is a cross-sectional view for describing the concept of the apparatus manufacturing a segment main body from reinforced concrete in accordance with another embodiment of this invention;

Fig. 19 is a cross-sectional view for describing an apparatus for molding resin coating material which covers the exterior surface of the segment main body of reinforced concrete in accordance with still another embodiment of this invention; Fig. 20 is a cross-sectional view for describing an apparatus, in accordance with yet another embodiment, which manufactures a segment main body of reinforced concrete on which recesses for the purpose of forming ribs are formed;

Fig. 21 is a cross-sectional view for describing an apparatus for molding resin coating material which has ribs and covers the exterior surface of the segment main body;

Fig. 22 is a schematic representation of a shield tunnel which employs existing segments; and

Figs. 23A, 23B and 23C are fragmentary views showing the profile of each of the segments shown in Fig. 22. BEST MODES FOR PRACTICING THE PRESENT INVENTION

With reference to the accompanying drawings , this invention will be described in detail .

Fig. 1A is a top view of trapezoidal resin coating material used in a trapezoidal resin-coated segment in accordance with one embodiment of the invention. Fig. IB is a cross-sectional view of the trapezoidal resin coating material taken across line X-X' shown in Fig. 1A, and Fig. IC is a cross-sectional view of the trapezoidal resin coating material taken across line Y-Y' shown in Fig. 1A. Fig. 2 is a cross-sectional view of the trapezoidal resin coating material taken across line Z-Z ' shown in Fig. 1A. Fig. 3A is a fragmentary cross-sectional view of an upper part of an anchor rib shown in Fig. 2, and Fig. 3B is a fragmentary cross-sectional view of a lower part of the anchor rib shown in Fig. 2.

As shown in Figs. 1 through 3, the trapezoidal resin coating material 11 comprises, e.g., a curved bottom plate 12; a longer side surface 13 (serving as a bottom side surface in Fig. 1A) which comes into contact with one ring; a shorter side surface 14 (serving as a top side surface in Fig. 1A) which comes into contact with another ring; a grout inlet 15 through which grout is filled into the clearance between the hole excavated by a shield tunneling method and a shield tunnel consisting of the trapezoidal resin-coated segments after the shield tunnel has been assembled; openings 16 into which bolts and nuts are inserted in order to join the trapezoidal resin-coated segments together; anchor pins 17 provided on the bottom plate 12 in order to prevent the trapezoidal resin coating material 11 from being separated from concrete; anchor ribs 18 which are provided along the joint surfaces of the resin coating material 11 in the axial direction of the shield tunnel in order to prevent the trapezoidal resin coating material 11 from being separated from the concrete to be filled into the resin coating material 11; and anchor ribs 19 which are provided along the joint surface of the resin coating material 11 in the circumferential direction of the shield tunnel for the same purposes as the anchor ribs 18. The bottom plate 12 of the trapezoidal resin coating material 11 has an unillustrated arch-shaped curved surface. The curved surface is divided into, e.g., six segments, in such a way that the segments have the identical profile. The trapezoidal resin coating material 11 has joint walls in the direction perpendicular to the axis of the shield tunnel . As can be seen from Fig. IB, since the trapezoidal resin coating material 11 is trapezoidal, the material is provided with the curved longer side surface 13, which will serve as the joint wall, and the curved shorter side surface 14, whereby a space having a substantially rectangularly C-shaped cross section is formed between the side surfaces 13 and 14.

Although not shown in the drawing, joint walls may be further formed along non-parallel sides of the trapezoidal resin coating material 11. In other words, the trapezoidal resin coating material 11 may be formed into a trapezoidal material which has five closed surfaces and one open upper surface used for filling concrete into the material.

As can be seen from Fig. IC, bolt holes 22 are formed in the areas of the longer side surface 13 and the shorter side surface 14 corresponding to the openings 16 so that the trapezoidal resin-coated segments can be joined together in the axial and circumferential directions of the shield tunnel. Unillustrated frames or concrete molds, which enable the formation of seal indentations 21 (see Fig. 4E which will be described later) and the bolt holes 22 by filling the trapezoidal resin coating material 11 with the concrete, are attached to non-parallel side surfaces 20 of the trapezoidal resin coating material 11.

The grout inlet 15 is formed at the center of the bottom plate 12 of the trapezoidal resin coating material 11, and a short tube is inserted into the grout inlet 15. As a result, a through hole is formed after the concrete has been filled into the trapezoidal resin coating material 11.

The openings 16 are used for joining together the resin-coated segments equipped with couplings, such as steel bolt boxes, by means of bolts and nuts.

The anchor pins 17 are intended for preventing the trapezoidal resin coating material 11 from being separated from the filled concrete. For this reason, the anchor pins 17 are not provided at right angles to the curved bottom plate 12 when they are integrally molded with the trapezoidal resin coating material 11 but are aligned in the direction in which the mold is removed from the trapezoidal resin coating material 11.

For example, a compressive stress ranging from 1,000 t/m² to 10,000 t/m² acts on the inside of the tunnel. Even in a case where the resin coating material or reinforced concrete has compressed strength for material, if the foregoing compressive stress acts on the box-shaped trapezoidal resin-coated segment, there is the risk of the segment being ruptured owing to the deteriorated adhesion of the resin coating material to the reinforced concrete.

Figs . 4A to 4C are schematic representations for describing another different example of the anchor pin of the present embodiment, and Fig. 4D is a schematic representation for describing a fragment of the trapezoidal resin-coated segment in accordance with the present invention.

As illustrated in Figs. 4A to 4C, various types of anchor pins 17 may be considered. For example, although anchor pins 41, 44, and 47 are fitted into the identical bottom plate 12 as shown in Figs. 4A to 4C, at least one type of anchor pin may be inserted into the bottom 12 by molding. Indentations 42 are formed to receive the base of each of the anchor pins shown in Figs. 4A and 4B in order to improve the adhesion of the anchor pins to the bottom plate 12.

Further, in order to make it easy for the anchor pin 44 to hold the concrete, a through hole 45 is formed in the anchor pin 33. This holding section may be formed into indentations or protuberances instead of into the through hole 45.

A thread 48 is cut in the entire surface of the anchor pin 47 shown in Fig. 4C . The anchor pin 47 may be attached to a threaded screw or to a screw which is inserted into the bottom plate 12 by molding.

Further, the anchor pin 47 can be inserted into the bottom plate 12 by molding, as are the anchor pins 41 and 44. In this case, the indentations 42 formed in the bottom plate 12 can be omitted. Moreover, the helical thread 48 may be formed in to an uneven pattern such as projections and depressions on the surface of reinforcing steel.

Since each of the anchor pins 41, 44, 47 has the holding section, the separation of the trapezoidal resin coating material 11 from the concrete is eliminated.

An anchor plate may be used as the foregoing anchor member in place of the anchor pin.

As shown in Figs. 3A and 3B, the anchor rib 18 is made up of a protuberance 23 having a substantially-circular cross section and a plate portion 24. The longer side surface 13 and the shorter side surface 14 are formed integrally with the bottom plate 12. The thickness of each of the protuberance 23 and the plate portion 24 gradually increases toward the base of each of them to thereby form a protuberance 23' and a plate portion 24'. This profile of the anchor rib 18 is intended to facilitate the removal of the mold when the trapezoidal resin coating material 11 is molded. Further, the protuberance 23, 23' of the anchor rib 18 prevent the creation of clearance which would otherwise be caused by the separation of the concrete filled into the trapezoidal resin coating material 11 from the longer side surface 13 and the shorter side surface 14. In comparison with the anchor ribs 18, the anchor ribs 19 are intended to increase the strength of the joint surface in the circumferential direction and are integrally formed with the bottom plate 12. Unillustrated concrete molds are attached to the sides of the trapezoidal resin coating material 11 on which the anchor ribs 19 are molded, and the concrete is filled into the resin coating material 11. After the removal of the concrete molds, the concrete becomes exposed, and the seal indentations are formed in the exposed surface of the concrete. Further, the anchor pins 17, the anchor ribs 18 and 19, the longer side surface 13, and the shorter side surface 14 are aligned not in the direction perpendicular to the bottom plate 12 but in the direction in which the molds are removed from the trapezoidal resin coating material 11 after the resin coating material 11 has been molded. More specifically, all these elements are directed in the vertical direction, and the trapezoidal resin coating material 11 can be easily molded. Further, the trapezoidal resin coating material 11 can adhere well to the thus-filled concrete.

Since the trapezoidal resin coating material 11 is made of resin, which will be described later, a significant difference in coefficient of heat wave expansion arises between the resin coating material 11 and the concrete. As a result, expansion due to the hardening heat of the concrete or shrinkage due to the cooling of the concrete arises between the trapezoidal resin coating material 11 and the concrete, causing the trapezoidal resin coating material 11 and the concrete to become apt to separation from each other. In the present embodiment, the size of the anchor pins 17, the thickness of the plate portion of the anchor ribs 18, 19, or the size of the protuberance of the anchor ribs 18, 19 is determined in consideration of the thermal expansion or shrinkage, the weight of the concrete, or vibration caused at the time of construction or installation.

In Fig. 4E, the thickness of the trapezoidal resin-coated segment comprises a side surface 55 of the trapezoidal resin coating material 11 and a side surface 57 of the concrete 20. The concrete is formed until it covers an edge 56 of the anchor rib 18 connected to the side surface 55 of the trapezoidal resin coating material 11. In short, the concrete is formed in such a way that the side surface 57 becomes flush with the side surface 55 of the trapezoidal coating material 11.

The seal indentations 21 into which a sealant is filled to prevent water seepage between the trapezoidal resin-coated segments are formed in the side surface 57 of the concrete by means of unillustrated concrete molds .

Next, the manufacture of the trapezoidal resin coated segment will be described. The trapezoidal resin coating material 11 is manufactured in the form as shown in Figs . 1 through 4 by pouring, into an unillustrated mold, a norbornane-based monomer, e.g., dicyclopentadiene, and reaction-injection molding material principally consisting of a metathesis-catalyst-based substance .

The reaction-injection molding material is made by preparing a first liquid consisting of a norbornane-based monomer and a metathesis-catalyst-based substance and a second liquid consisting of a norbornane-based monomer and an activator; and mixing together these two liquids by means of a mixing head. The thus-prepared molding material is poured under reduced pressure into the mold of a reaction-injection molding apparatus .

More specifically, the reaction-injection molding material is made of norbornane-based monomers, e.g., dicyclopentadiene as disclosed in Japanese Patent Publication (kokoku) Nos. Hei-3-28451, 4-9812, 6-13563, USP Nos . 4,440,340, 4418,179, and EP Nos. 84,888 and 10,781. The resin-coated segment, in accordance with the present invention, can be manufactured from these materials. Although a material (which is available from NIHON ZEON Co., Ltd. under the tradename of "PENTAM") is used in the present embodiment, another material (which is available from TEIJIN METTON Co., Ltd. under the tradename of "METTON") is also usable. In addition, similar materials are available from B.F. GOODRICH Co., Ltd. or METTON AMERICA, INC.

Other than the hardening resin which principally consists of a norbornane-based monomer and a metathesis-catalyst-based substance, a resin coating material used for manufacture of the resin-coated segment can be obtained by heating or pressurizing a sheet molding compound set in a mold.

The concrete is filled into the concrete mold after the resin coating material 11 and couplings, such as reinforcing steel or bolt boxes, have been placed in the concrete mold. During the course of the filling of the concrete, the concrete mold is vibrated while being held on a shaking table, and the concrete filled in the mold is compacted through use of a rod-shaped vibrator or the like. The vibration is good for filling the concrete into the mold but vibrates the side surfaces 13, 14 to thereby create clearance along the interface between the side surfaces and the concrete.

The inventors of the present patent application have found this problem encountered in the manufacture of the resin-coated segment. To solve this problem, the inventors have fit a retaining spacer to the reinforcing steel provided along the side surfaces 13, 14. The retaining spacer presses the side surfaces of the resin coating material 11 against the resin-coated segment mold, thereby enabling prevention of vibration. As a result, the concrete can be thoroughly filled into the mold without clearance. The retaining spacer may be made of any synthetic resin, so long as the resin has slight resilience. Further, the retaining spacer may be formed into any shape, so long as, when being fitted to the reinforcing steel, the spacer can retain an interval between the reinforcing steel and the side surfaces of the rein coating material 11 and can be pressed against the resin-coated segment mold.

For example, the retaining spacer has a substantial ring shape and is comprised of an inner ring portion having a hole for receiving the reinforcing bar, a partially-cut-away outer ring portion, and radial bridge portions connected between the inner and outer ring portions.

Next, the method of constructing the tunnel is described upon reference to the assembly of the trapezoidal resin-coated segment. Figs. 5A and 5B are schematic representations for describing a joint between the trapezoidal resin-coated segments. Fig. 6 is a diagrammatic representation showing the tunnel constructed by assembly of the trapezoidal resin-coated segments in accordance with the present embodiment .

In Fig. 6, a ring 67 is constituted by stacking six trapezoidal resin-coated segments 61, 62, 63, 64, 65, 66 into a ring shape in a circumferential direction. The trapezoidal resin-coated ring segments 61 through 66 are alternately arranged in opposite directions in such a way that the longer side surface 13 and the shorter side surface 14 are placed side by side each other. As shown in Fig. 5A, concrete portions 53 are brought into contact with each other at each of interfaces 51 between the trapezoidal resin-coated segments 61 to 66, and the seal indentations 21 are filled with an unillustrated sealant .

The trapezoidal resin-coated segments 61 to 66 are stacked from bottom and are joined together by means of bolts and nuts by utilization of the openings 16. For example, the final trapezoidal resin-coated segment 63 is slid sidewise into the space between the trapezoidal resin-coated segments 62 and 64, and they can be joined together by bolts and nuts. In comparison with the conventional shielding tunneling method in which the trapezoidal resin coated segment is fitted into a corresponding space from below, the sideway fitting of the segment into the space, as in the present embodiment, is simpler.

As described above, one ring is completed by joining together the six trapezoidal resin-coated segments 61 through 66. As previously described, the trapezoidal resin-coated segments are sequentially assembled into rings. As shown in Fig. 5B, the thus-assembled segments are sealed with a sealant in the circumferential direction to thereby construct a shield tunnel .

The openings 16 (see Fig. 1) which permit the joining of the segments through use of bolts and nuts are filled with, e.g., mortar or a foaming agent. Closures which are made of the same material as that of the resin coating material 11 are fitted to the bolt holes 22 and the grout inlet 15, so that the surface of the segment becomes substantially smooth as is the interior surface of the shield tunnel.

Fig. 7A shows a segment in accordance with another embodiment of the invention, in which the concrete becomes exposed inside the shield tunnel, and Fig. 7B shows another type of segment, in which the resin coating material becomes exposed.

A trapezoidal resin-coated segment 71 shown in Fig. 7A is different from the segment having three closed surfaces in accordance with the previous embodiment and has five closed surfaces. More specifically, the trapezoidal resin-coated segment 71 has a bottom 72 and four side frames 73, and the space defined by the bottom and the side frames is filled with concrete 74. In the case of this embodiment, the anchor ribs similar to those shown in Figs. 3A and 3B are provided along the four side frames 73.

Fig. 7A shows the end face of each of couplings 75 which are made of steel bolt boxes and are provided in the openings 16. Unillustrated anchor reinforcing steel connected to both ends of the coupling 75 maintains the strength required for connection of the resin-coated segments. After the construction of the shield tunnel, the trapezoidal resin-coated segments 71 become exposed inside the tunnel. Since the outer peripheral surface of the shield tunnel is coated with resin, the resistance of the tunnel to ground water is improved, and the inside of the tunnel becomes resistant to fire. In short, the shield tunnel comprised of the trapezoidal resin-coated segments shown in Fig. 7A is used as freeways, railways, or roads .

A resin-coated segment 71' shown in Fig. 7B whose resin portion becomes exposed inside the shield tunnel and has five closed surfaces as does the resin-coated segment 71 shown in Fig. 7A. After the construction of the shield tunnel, the resin portions of the segments become exposed inside the tunnel. Since the inner periphery of the shield tunnel becomes coated with resin, such a shield tunnel is suitable for use as sewers or drains .

Although the thickness of the resin side frame 73 shown in Figs. 7A and 7B ranges 5 to 10 mm, it can be increased if the resin-coated segment requires higher strength.

Fig. 8 is a schematic representation for describing a hexagonal resin-coated segment in accordance with still another embodiment of this invention. A hexagonal resin-coated segment 81 having a resin-coated interior surface shown in Fig. 8 has two longer sides and four shorter sides and is longitudinally curved. In other words, the hexagonal resin-coated segment 81 has the shorter sides, or joint surfaces 82 to be joined together in the circumferential direction of the shield tunnel, and the longer sides, or joint surfaces 83 to be joined together in the axial direction of the tunnel. Particularly, since a shield jack of a shield machine comes into contact with the joint surfaces 83, the joint surfaces 83 are oriented at right angles to the axis of the shield tunnel. The shield machine excavates the tunnel in a forward direction while pressing a joint surface 84 through use of the shield jack.

Fig. 9 is a schematic representation for describing a rectangular resin-coated segment in accordance with yet another embodiment of this invention. Fig. 10 is a schematic representation for describing the joint between the segments shown in Fig. 9.

As shown in Figs. 9 and 10, a rectangular resin-coated reinforced concrete segment 91 comprises a grout inlet 92 formed at the center of the segment; a plurality of openings 93 for receipt of bolts 95 and nuts 96; bolt holes 94 for receipt of bolts to be used for joining the segment to another segment; and resin coating material 98. The reinforced concrete segment 91 has a curve which is determined by the number of segments and the diameter of the tunnel and is imparted with the required strength by unillustrated reinforcing steel.

The grout inlet 92 is a hole used for filling grout into the clearance between the tunnel excavated by the shield tunneling method and the reinforced concrete segments 91. The openings 93 used for inserting the bolts 95 and nuts 96 are formed in order to join together the adjoining reinforced concrete segments 91.

After having been inserted into the bolt hole 94 through the opening 93, the bolt 95 is fastened by means of the nut 96 inserted into the opening 93 of the adjoining reinforced concrete segment 91. In short, the opening 93 is formed into the shape suitable for joining together the segments through use of the bolt 95 and the nut 96 inserted in the opening.

In this embodiment, the resign coating material 98 is formed to a thickness of 80 % or less, more preferably 20 to 70 %, of the side wall of the reinforced concrete segment 91, and the remaining of the side wall is formed from the concrete member 97.

A seal indentation 99 is formed in the concrete member 97. With the construction of the previously-described joint wall, the manufacture of the resin coating material and the resin-coated segment are facilitated. Fig. 11 is a schematic representation for describing coupling means, in accordance with a further embodiment, which joins together the reins-coated segments through use of bolts and nuts .

In Fig. 11, resin-coated segments 110, 110' are each made up of concrete 111, 111' and resin coating material 112, 112'. Bolt boxes 113, 113' are respectively welded to reinforcing bars 114, 114' fixedly embedded in the concrete 111, 111'. A hole for receipt of a bolt 115 is formed in the side of the bolt box 113 to be joined to another bolt box of another segment.

For example, the resin-coated segments 110 and 110' are joined together by inserting the bolt 115 into the bolt hole formed in the bolt box 113, and a nut 116 is screwed to the bolt 115 from another bolt box 113' formed in the segment 110'. This nut 116 is then fastened. Subsequently, the openings of the bolt boxes 113, 113' are closed by bonding closures 117, 117' to the openings, and sealants 118, 118' are filled into the clearance between the concrete members 111, 111' in order to maintain the water-tightness of the thus-joined segments.

Fig. 12 is a schematic representation for describing coupling means, in accordance with a still further embodiment of the invention, which joins together the resin-coated segments by means of through bolts . The embodiment illustrated in Fig. 12 is different from that shown in Fig. 11 in that the outside of the shield tunnel is coated with the resin coating material, and the bolts and the bolt boxes shown in Fig. 12 are different in shape from those shown in Fig. 11. For example, through bolts 125, 125' are longer than the bolts employed in the previous embodiment . Accordingly, before the resin-coated segments 110, 110' are joined together, the through bolts 125, 125' inserted into either a pair of bolt guide holes 127, 127' or another pair of holes 128, 128.' Subsequently, the other resin-coated segment 110' is joined to the segment 110, and the through bolts 125, 125' are moved to the center of the interface between the segments 110, 110.' Nuts 126, 126' are screwed to both sides of the respective bolts 125, 125' from bolt boxes 123, 123.'

Fig. 13 is a schematic representation for describing joining means, in accordance with a yet further embodiment of this invention, which joins together the resin-coated segments through use of curved bolts.

The embodiment illustrated in Fig. 13 is different from that shown in Fig. 12 in that the inside of the shield tunnel is coated with the resin coating material, and the bolt and the bolt boxes shown in Fig. 13 are different in shape from those shown in Fig. 12. For example, a curved bolt 135 has an arc shape, and bolt boxes 133, 133' are formed into the shape which facilitates the insertion of the bolts or the fastening of nuts. After resin-coated segments 130, 130' have been attached to each other, the curved bolt 135 is inserted into one of the bolt boxes 133, 133.' The curved bolt 135 is fastened at both ends by means of nuts 136, 136.'

The bolt boxes 133, 133' can be made compact as a result of the use of the curved bolt 135, and hence this type of resin-coated segment is suitable for use in a thin shield tunnel .

Figs . 14A and 14B are schematic representations for describing joining means, in accordance with an additional embodiment of this invention, which joins together the resin-coated segments through use of tapered hardware.

In Figs. 14A and 14B, couplings are attached to the resin-coated segments 130, 130' in the circumferential direction and axial direction of the tunnel. The coupling is made up of two pieces of C-frame hardware 143, 143,' each of which has a tapered joint portion. After the pieces of hardware 143, 143' have been attached to each other, a piece of H-frame hardware 145 having a tapered recess is fitted on the thus-joined hardware 143, 143' from below. The pieces of C-frame hardware 143, 143' are fixed to the concrete filled in the resin-coated segments by means of reinforcing steel 144, 144. ' The hardware having the foregoing profile enables the resin-coated segments 130, 130' to be joined together readily and speedily.

Fig. 15 is a schematic representation for describing joining means, in accordance with still another embodiment of this invention, which joins together the resin-coated segments through use of diagonal bolts .

In Fig. 15, a bolt box 153 having a diagonal bolt hole is formed in the resin-coated segment 130. A nut 156 in the internal surface of which a thread 154 is cut is inserted into the other resin-coated segment 130,' and an oblique bolt 155 is to be screwed into the nut 156. After the resin-coated segments 130, 130' have been attached to each other, the oblique bolt 155 is inserted into the bolt box 153 and is screwed to the nut 156 to thereby join together the segments.

Fig. 16 is a schematic representation for describing joining means, in accordance with yet another embodiment of this invention, which joins together the resin-coated segments through use of knuckle pins .

A hole into which a pin 162 is fitted is formed in recessed hardware 161 embedded in the resin-coated segment 130. The pin 162 is fixed in the resin-coated segment 130.' The recessed hardware 161 and the pin 162 are fitted together in such a way that the pin 162 can expand or contract by means of resiliency.

As in the case of the embodiments shown in Figs. 13 and 14, the embodiments shown in Figs. 15 and 16 require compact bolt boxes and enable the resin-coated segments to be joined together readily and speedily.

The joining means previously described in the embodiments may be replaced with other publicly-known means or another means having comparable features .

Fig. 17A is a schematic representation for describing a shield tunnel in accordance with a furthermore embodiment of this invention, in which the tunnel is constructed by joining together, in the circumferential and axial directions of the tunnel, substantially-trapezoidal resin-coated segments of varying sizes whose both sides are graded at a given angle with respect to the axial direction of the tunnel. Fig. 17B is an exploded view showing the substantially-trapezoidal resin-coated segments joined in the circumferential direction of the shield tunnel. Fig. 17C is a diagrammatic representation for describing a curved shield tunnel constructed by joining together the substantially-trapezoidal resin-coated segments in such a way that the shorter sides and the longer sides of the segments are respectively connected to each other. In Fig. 17A, a shield tunnel 171 is constructed from, e.g., six substantially-trapezoidal resin-coated segments of varying sizes. The substantially-trapezoidal resin-coated segment has two joint surfaces 101, 102 which each form a predetermined anglea |=with respect to the line perpendicular to the axis of the shield tunnel. Further, the other joint surfaces of the segment are formed in such a way that imaginary extensions of the joint surfaces 101, 102 form an angle of 2a(=.

The shield tunnel 171 is constructed by stacking the segments one on top of the other so as to constitute a ring in the circumferential direction of the shield tunnel in such way that a bottom side 172 and an upper side 173 are arranged in alternate directions so as to create a joint surface 174 between the segments .

Fig. 17C is an exploded view of the curved shield tunnel constructed from the six substantially-trapezoidal resin-coated segments of varying sizes. Some of the segments have the longest side surface 103 and the shortest side surface 104. As shown in Fig. 17A, the segments are linearly aligned by connecting together the longest side surfaces 103, and by connecting together the shortest side surfaces 104.

Further, as shown in Fig. 17B, if the segments are joined together in such a way that the shortest side surfaces 104 or the longest side surfaces 103 become arranged side by side to each other in the axial direction of the shield tunnel, a curved shield tunnel is constructed. Fig. 18 is a cross-sectional view for describing the concept of the apparatus manufacturing a segment main body from reinforced concrete in accordance with another embodiment of this invention. Fig. 19 is a cross-sectional view for describing an apparatus for molding resin coating material which covers the exterior surface of the segment main body of reinforced concrete in accordance with still another embodiment of this invention.

As shown in Fig. 18, a lower mold 1811 of reinforced concrete used for molding a segment main body is formed in such a way that the outer surface of the lower mold 1811 has the same circular-arch shape as that of the interior surface of an outer-surface resin-coated segment. A first side mold 1812 of reinforced concrete used for molding the segment main body and a second side mold 1813 of reinforced concrete used for molding the segment main body are arranged so as to symmetrically move in opposite circumferential directions along a substantially circular-arc path. Further, the first slide mold 1812 is used for manufacturing, from reinforced concrete, circumferential joint walls 18151 of a segment main body 1815 to be joined to another segment.

Although not shown in the drawing, there are two additional side molds which can move in the axial direction and are used for forming axial joint walls 18152 of the outer-surface resin-coated segment.

Graded projections 18121 and 18131 are formed along the longitudinal lower edges of the first and second side molds 1812 and 1813. As a result, the segment main body 1815 is formed to have a truncated trigonal pyramid portion 18153 at the intersection of the interior surface and the two joint walls 18151 and 18152.

The truncated trigonal pyramid portion 18153 formed in the previous embodiment may be formed into a truncated semi-circular cross section other than the truncated trigonal pyramid shape shown in Fig. 18. The height and size of the lower mold 1811 and the first and second side molds 1812, 1813 depend on the size or required strength of a construction.

Bolts used for joining adjacent segments together, bolt boxes formed to the size and shape which permit the fastening of nuts through use of a tool, grout inlet hardware used for pouring grout into the mold, reinforcing steel cage, and sheathed tubes which are used for insertion of the bolts and joined to reinforcing steel, are provided in the mold formed by the lower mold 1811 and the first and second side molds 1812 and 1813, as required. An upper mold 1814 of reinforced concrete which is used for forming a segment main body and has a concrete inlet 18141 formed therein is placed on the foregoing mold. Subsequently, concrete is poured and filled into the mold from the concrete inlet 18141. During the course of the filling of concrete, the mold is vibrated on an unillustrated shaking table, and the thus-filled concrete is compacted by means of a rod-shaped vibrator or the like.

The concrete in the vicinity of the concrete inlet 18141 is made uniform by means of a trowel. The upper mold 1814 is moved in an upward direction, and anchor pins 19154 shown in Fig. 19 are driven into the segment main body 1815 before the concrete sets, as required. Preferably, the anchor pins are made of steel or resin, and a nailing machine which drives a pin by virtue of hydraulic or mechanical force is used.

A segment main body 1915 formed from reinforced concrete into a segment is transferred to a resin coating material forming base table 1921 of reinforced concrete having substantially the same profile as that of the lower mold 1811, as required. First and second side molds 1922 and 1923 used for forming resin coating material are provided on the base table 1921 while clearance is maintained between the joint walls 18151 of the segment main body 1815 and the side molds 1922 and 1923. The side molds 1922 and 1923 are each provided with first and second seal groove formation protuberances 19221 and 19222 which protrude toward the inside of the molds. Similarly, molds used for forming resin coating material are provided in the vicinity of the axial joint walls 18152 of the segment main body 1815.

At least one resin inlet 19231 is formed in the second side wall 1923. An upper mold 1924 used for molding resin coating material is placed above the first and second side molds 1922 and 1923 while required clearance is maintained between the exterior surface of the segment main body 1915 of reinforced concrete and the side molds 1922 and 1923. An air vent hole 19241 is formed in the upper mold 1924.

When rein coating material 1951 is poured into the mold from a resin inlet 19231, air escapes from the air vent hole 19241, whereby the material is filled into the mold.

After the resin coating material 1925 has set, the resin coating material forming molds are removed, whereby an exterior-surface resin-coated segment is manufactured. The anchor pins 19154 bring the segment main body 1915 into close contact with the resin coating material 1925, and hence the resin coating material 1925 is not separated from the segment main body 1915.

The resin coating material 1925 enters the space between the side molds and a truncated trigonal pyramid portions 19153 formed along the segment main body 1915, and the material contracts while setting. As a result, the resin coating material 1925 holds the segment main body 1915 to thereby make it difficult for the segment main body 1915 to be separated from the segment main body 1915. When the segment main body 1915 is coated with the resin coating material 1925 by reaction-injection molding, the main body 1915 is heated to 40 to 90ϋA, more preferably to 60 to 80uA, in order to promote the setting of the resin. Further, a coating film is formed on the surface of the segment main body 1915 in advance by applying a coating film of olefin-based resin on, or by adhering a film to, the surface. This coating film contributes to improvements in the adhesion or setting properties of the resin coating material. A coating film or a film may be applied or adhered to the surface of the segment main body 1915 by means of the known means.

Fig. 20 is a cross-sectional view for describing an apparatus, in accordance with yet another embodiment, for manufacturing, from reinforced concrete, a segment main body on which recesses used for forming ribs are formed. Fig. 21 is a cross-sectional view for describing an apparatus for molding resin coating material which has ribs and covers the exterior surface of the segment main body.

The present embodiment is different from the previous embodiment in that the resin coating material used for covering a segment main body 2051 is provided with ribs. More specifically, in Fig. 20, a lower mold 2051 of reinforced concrete used for forming a segment main body is placed upside down with respect to the mold used in the previous embodiment . In order to increase the strength of the resin coating material which covers the segment main body 2015, ribs are formed on the resin coating material.

For example, protuberances 20511 used for forming ribs are formed in a lattice pattern on the lower mold 2051 in order to form ribs on the surface of the resin coating material. After predetermined hardware, e.g., a reinforcing steel cage, has been placed in the mold, concrete is filled into the mold from a concrete inlet 20541.

During the course of the filling of concrete, the mold is vibrated on a shaking table, and the thus-filled concrete is compacted by means of a rod-shaped vibrator or the like. The segment main body 2015 is molded so as to have the protuberances 20511 used for forming ribs, seal grooves, and notches 20157 by the lower mold 2051 having the protuberances 20511 and the first and second side molds 2052 and 2053, each of which has a protuberance 20521 used for forming a seal groove and a protuberance 20522 used for forming resin coating material .

The ribs formed in the embodiment may be formed only in one direction of the segment or in an intermittent manner other than in the lattice pattern. Further, the shape of the front end of the rib may be changed to another shape. The segment main body 2015 is provided on a resin coating material molding base table 2121 after having been turned upside down. Subsequently, a first side mold 2162 used for molding resin coating material, a second side mold 2163 used for molding resin coating material, and an upper mold 2124 used for molding resin coating material are provided around a segment main body 2115 of reinforced concrete while a given interval between the main body 2115 and the molds is maintained. Resin coating material 2165 is pressed into the mold from a resin inlet 21631 while air is released from an air vent hole 21241.

Although the explanation has been given of the exterior-surface resin-coated segment in the previous embodiment, an interior-surface resin-coated segment may be manufactured by a substantially-similar method.

In accordance with the present invention, the resin coating material is attached to the mold used for molding reinforced concrete, the application of a release agent to the mold, the efforts required for removal of the segment from the mold, and the cleaning of the mold can be facilitated.

In accordance with the present invention, in a case where the resin-coated segments are arranged in such a way that the coating material of the segments faces the inside of the tunnel, the secondary lining operation can be omitted. Since the coating material has superior chemical resistance and a smooth surface, the flow rate of rainwater or sewage is increased. As a result, a shield tunnel for use as drains or sewers having superior hydraulic characteristics can be constructed.

In accordance with the present invention, in a case where the resin-coated segments are arranged in such a way that the coating material of the segments faces the outside of the tunnel, the water-tightness of the shield tunnel is improved. Further, the concrete portion of the segments faces the inside of the tunnel, the tunnel becomes resistant to fire. As a result, a shield tunnel for use as railways, freeways, or underground multipurpose ducts, can be constructed.

In accordance with the present invention, since anchor pins or plates are embedded in the resin coating material, the resin coating material is prevented from being separated from concrete. Accordingly, a resin-coated segment which consists of the resin coating material integrally formed with concrete and has strength can be manufactured.

In accordance with the present invention, the resin-coated segment is manufactured by coating a segment main body with resin coating material. This method requires only inexpensive molds, and the resin coating material contracts while setting. As a result, the adhesion of the segment main body to the resin coating material can be improved. In accordance with the present invention, since curved bolts are used for joining interior-surface resin-coated segments together, the bolt boxes can be made compact. Accordingly, even if a tunnel having a comparatively small thickness is constructed, the strength of this tunnel can be improved .

In accordance with the present invention, since the interior-surface resin-coated segment is formed into a trapezoidal or hexagonal shape, a tunnel can be constructed from only one type of segment. Accordingly, molds used by the molding machine become inexpensive, and the method of constructing a tunnel becomes simple.

INDUSTRIAL UTILIZATION OF THE INVENTION

As has been described in detail, the present invention is not limited to the previously-described embodiments. Redesigns of the invention are conceivable, so long as they fall within the scope of the claimed invention.

The resin-coated segment having a trapezoidal, hexagonal, or rectangular-parallelepiped shape described in the embodiments may be formed into a tortoise shape, a triangular shape, a square shape, or others.

Although the six substantially-trapezoidal resin-coated segments are described in the embodiments, the segments are not limited to this number. Although the resin-coated segments in accordance with the embodiments have been described with reference to, for example, tunnels for use as freeways, railways, sidewalks or shield tunnels for use as drains or sewers, they may be used for construction of sewers, water supplies, industrial water works, underground multipurpose ducts , underground rivers , underground tanks , ground tanks or vessels, or the like. These constructions are not limited to a circular profile but may be formed into a semi-circular shape, an oval shape, a polygonal shape, or a multiple shape consisting of various shapes in combination. Even in this case, the resin-coated segment of the present invention can be used, as in the case of the previous embodiments.

Although the reaction-injection molding of a resin mold for use with the resin-coated segment or the method of manufacturing reinforced concrete are not described in detail, known means may be employed.

The same applies to the formation of the openings through which bolts and nuts are inserted or the manufacture of couplings or retaining spacers .

The profile of the couplings, such as bolt boxes, which receive bolts and nuts is easily changed to any profile other than the profile employed in the embodiments, in consideration of the operating efficiency or the thickness of a shield tunnel .

Although the detailed explanation has been given of the segment main body of reinforced concrete, the main body may be formed from steel segments, ductile segments, or composite segments composed of concrete and combinations thereof.

Rivets, T-shaped members, or members having bulging sections for purposes of preventing disconnection of the member, may be fixed, as anchor members, to the steel segment by electric welding. In addition to anchor members like rivets, strip-shaped members or strip-shaped members having through holes formed therein may be provided as anchor members in the axial or circumferential direction or in one direction.

The anchor member may be formed of plastics other than of metal. Further, the segment and concrete can be formed from well- or publicly-known material.

In accordance with the present invention, well- or publicly-known thermosetting resin or an unset sheet-like substance which consists of reinforced fibers such as glass fibers, a filler, and thermosetting resin may be used as resin in addition to the resin used in the embodiments.

Although the resin coating material is integrally formed with the bolt boxes in the embodiments , separately-formed bolt boxes may be integrally bonded to the resin coating material.

Claims

1. A resin-coated segment used for constructing a shield tunnel by assembly of a plurality of segments, wherein the improvement being characterized by comprising: a segment main body; resin coating material including a bottom plate for covering at least one of the surfaces of the segment which serves as either an interior or exterior surface of the shield tunnel ; and anchor members embedded in the segment main body and the resin coating material.

2. The resin-coated segment as defined in claim 1, wherein the resin coating material is made of hardening resin and includes a bottom plate for covering one of the surfaces of the segment which serves as either the interior or exterior surface of the shield tunnel.

3. The resin-coated segment as defined in claim 1, wherein the resin coating material is made of hardening resin and includes two joint walls which serve as joint surfaces perpendicular to the axial direction of the shield tunnel and a bottom plate for covering one of the surfaces of the segment which serves as either the interior or exterior surface of the shield tunnel.

4. The resin-coated segment as defined in claim 1, wherein the resin coating material is made of hardening resin and includes all joint walls which serve as joint surfaces used for joining segments together and a bottom plate for covering one of the surfaces of the segment which serves as either the interior or exterior surface of the shield tunnel.

5. The resin-coated segment as defined in one of claims 1 through 4, wherein the bottom plate of the resin coating material is formed into a trapezoidal, rectangular, or hexagonal shape.

6. The resin-coated segment as defined in one of claims 3 through 5, wherein the joint walls of the resin coating material have anchor ribs .

7. The resin-coated segment as defined in one of claims 3 through 5, wherein the height of the joint walls of the resin coating material is 80% or less of the thickness of the resin-coated segment.

8. The resin-coated segment as defined in claim 1, wherein the anchor member is at least either an anchor pin or an anchor plate.

9. The resin-coated segment as defined in claim 1, wherein the hardening resin which forms the resin coating material is formed from reaction-injection molding material principally composed of norbornene-based monomer and a metathesis catalyst.

10. The resin-coated segment as defined in claim 1, wherein the hardening resin which forms the resin coating material is formed from fiber-reinforced plastics composed of a sheet molding compound principally including unsaturated polyester resin.

11. The resin-coated segment as defined in claim 1, wherein the segment main body is composed of a reinforced concrete segment, a steel segment, a ductile segment, or a composite segment composed of combinations thereof.

12. A method of manufacturing a resin-coated segment used for constructing a shield tunnel by assembly of the plurality of resin-coated segments, the method comprising the steps of: pouring liquid hardening resin into a coating material mold having anchor members provided therein by reaction-injection molding, so that resin coating material is formed in such a way that the anchor members are partially embedded in the bottom plate of the material which covers the interior or exterior surface of the resin-coated segment; and filling concrete into a segment mold after the resin coating material, reinforcing bars, and couplings have been set in the segment mold.

13. A method of manufacturing a resin-coated segment used for constructing a shield tunnel by assembly of the plurality of resin-coated segments, the method comprising the steps of: pouring liquid hardening resin into a coating material mold having anchor members provided therein by reaction-injection molding, so that resin coating material is formed to have at least two joint walls and one bottom plate for covering either the interior or exterior surface of the resin-coated segment in such a way that the anchor members are partially embedded in the bottom plate; and filling concrete into a segment mold while vibrating the segment mold so as to compact the thus-filled concrete after the resin coating material, reinforcing bars, and couplings have been set in the segment mold and retaining spacers have been fitted on reinforcing steel in close proximity to the joint walls so as to press the joint walls against the segment mold.

14. The resin-coated segment as defined in claim 12 or 13, wherein the hardening resin which forms the resin coating material is formed from reaction-injection molding material principally composed of norbornene-based monomer and a metathesis catalyst.

15. A method of manufacturing a resin-coated segment used for constructing a shield tunnel by assembly of the plurality of resin-coated segments, the method comprising the steps of: thermally curing a sheet molding compound set in a coating material mold having anchor members provided therein by pressing, so that resin coating material is formed in such a way that the anchor members are partially embedded in the bottom plate which covers the interior or exterior surface of the resin-coated segment; and filling concrete into a segment mold after the resin coating material, reinforcing bars, and couplings have been set in the segment mold.

16. A method of manufacturing a resin-coated segment used for constructing a shield tunnel by assembly of the plurality of resin-coated segments, the method comprising the steps of: thermally curing a sheet molding compound set in a coating material mold having anchor members provided therein by pressing, so that resin coating material is formed to have at least two joint walls and one bottom plate for covering either the interior or exterior surface of the resin-coated segment in such a way that the anchor members are partially embedded in the bottom plate; and filling concrete into a segment mold while vibrating the segment mold so as to compact the thus-filled concrete after the resin coating material, reinforcing bars, and couplings have been set in the segment mold and retaining spacers have been fitted on reinforcing steel in close proximity to the joint walls so as to press the joint walls against the segment mold.

17. A method of manufacturing a resin-coated segment used for constructing a shield tunnel by assembly of the plurality of resin-coated segments, the method comprising the steps of: manufacturing a segment main body which has anchor members and/or recessed formed on the exterior surface thereof; positioning a mold for molding coating material of hardening resin which covers the exterior surface and joint walls of the segment main body; forming the coating material from hardening resin principally composed of norbornene-based monomer and a metathesis catalyst within the mold by reaction-injection molding; and removing a resin-coated segment from the mold after the coating material has set.

18. A method of manufacturing a resin-coated segment used for constructing a shield tunnel by assembly of the plurality of resin-coated segments, the method comprising the steps of: manufacturing a segment main body which has anchor members formed on the interior surface thereof; positioning a mold for molding coating material of hardening resin which covers the interior surface and joint walls of the segment main body; forming the coating material from hardening resin principally composed of norbornene-based monomer and a metathesis catalyst within the mold by reaction-injection molding; and removing a resin-coated segment from the mold after the coating material has set.

19. The resin-coated segment manufacturing method as defined in any one of claims 17 and 18, wherein the segment main body is subjected to reaction injection molding after having been heated in advance .

20. The resin-coated segment manufacturing method as defined in any one of claims 17 and 18, wherein the segment main body is subjected to reaction injection molding after the resin has been applied to the main body in advance.

21. The resin-coated segment manufacturing method as defined in any one of claims 17 and 18, wherein the segment main body is a reinforced concrete segment, a steel segment, a ductile segment, or a composite segment composed of combinations thereof .