WO2002027142A1

WO2002027142A1 - Method and apparatus for continuously forming a concrete structure

Info

Publication number: WO2002027142A1
Application number: PCT/NO2001/000372
Authority: WO
Inventors: Knut Fossum
Original assignee: Knut Fossum
Priority date: 2000-09-12
Filing date: 2001-09-11
Publication date: 2002-04-04
Also published as: AU2001286338A1; NO20004536D0

Abstract

A method and an apparatus are developed for continuous forming of a concrete construction (2,3,18), such as lining for a tunnel or a subpassage (2,3), or a stand-alone concrete wall (18) by means of a concrete mixture and a slip form (6) with ancillary formwork trolley (5). The slip form (6) with ancillary formwork trolley (5) is arranged for guided movement along the tunnel; and end seal (12) which is fixedly anchored to the tunnel is established; at least one concrete extruder (16) is attached to the slip form (6) with ancillary formwork trolley (5); a preferably flexible sheet (10) is arranged, which substantially covers the surface (11) of the slip form (6), so that the slip form (6) may slide in relation to the sheet (10), and where the sheet (10) is adapted for removal after hardening of the concrete (27); and the formwork trolley (5) is moved forwardly while the concrete extruder (16) is operated and fills the formwork cross section (13) by supply near the forward end (14) of the slip form (6).

Description

Method and apparatus for continuously forming a concrete structure

Introduction

This invention relates to a method and an apparatus for continuous forming of a concrete construction, such as a lining for a channel or a subpassage, by means of a concrete mixture and a slip form with ancillary formwork trolley. The method and the apparatus according to the invention is also suitable for continuous forming of a stand-alone wall.. Background of the invention

By projecting concrete constructions generally, several factors should be evaluated when choosing the type of concrete that shall be used. Use of commonly known forming technology for concrete gives channels which are relatively safe against leakages but at the same time a very long. hardening time for the concrete is required and often under influence of pressure. The building process is therefore often cost consuming and inconvenient .

Moulding concrete cannot automatically be replaced by spraying concrete for several reasons, i.a. due to differences related to price and hardening time. The price for common moulding concrete is normally the half of the price for spraying concrete. Even with lower material costs for moulding concrete it will in many cases nevertheless be cost justified to choose spraying concrete instead of moulding concrete especially because the hardening process for the spraying concrete occurs in much shorter time than for moulding concrete. Shorter hardening times for the concrete results in shorter building time and thereby reduced working and operation costs. The above mentioned factors must be evaluated when choosing concrete type.

Conventional building of a tunnel cycle is normally carried out in the following way: boring and blasting work - loading and transport of free masses and blasted material away from the boring and blasting location geologically mapping clearing work and securing of rocks

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surface. Prior art

A solution which has been proposed to overcome the friction problem has been described in US 4 769 192. This publication relates to an arrangement for forming wet concrete by means of a slip form having a radial expandable outer shell and to add a fluid under pressure to the inner surface of the outer shell. The pressure of the fluid is pulsated such that the outer shell expands and retract to reduce the friction between the outer shell and the concrete. This results in that the form can be moved forwardly along the concrete with reduced scribing of the surface of the concrete.

A second solution to overcome this problem of large friction forces has been described in US 4 710 058. Here a tunnel lining machine divided in a front part, a middle part and a rear part to be used behind tunnel boring machines has been described. Forward driving mechanism is a conveyor. The conveyor bands rotates freely in relation to the frame of the machine. The forward driving mechanism itself supports the tunnel lining which shall be moulded. The tunnel lining machine shall have the capacity to obtain velocities between 9-18 m/hour (30-60 feet/hour) .

The middle part forms however a sealed inner surface for the fresh concrete which is pumped out in the ring space between the roller bands and the tunnel wall for forming the tunnel lining and a rear part which shall support the partly hardened concrete which has not yet been sufficiently hardened to be self supporting when it passes the middle part.

When such roller bands are used as forms for the tunnel lining there will exist a certain danger for leakage in the joints between the plate in the roller bands which abets against the tunnel wall. It has however, been tried to solve this problem by for example positioning packing of elastic material between the plates in the roller bands, possibly that the plates interlock in each other. The packing will be subjected to great wearing which results in that leakage nevertheless can be a problem during the time. It has also been mentioned that leakage of concrete may be reduced by- increasing the stiffness of the concrete or that the concrete pressure is reduced.

In US 4 451 176 there has been proposed a solution where a form in more parts which are adapted for demounting, moving and mounting is used. A method and an apparatus for tunnel boring with a driving shield to support the front end of the tunnel where the board material shall be removed has been described. At the rear end of the driving shield a tunnel lining to cover the tunnel wall is created. The lining is formed by spraying concrete backward directly into the space between the form and the tunnel wall itself.

The form consists of more ring elements which each consists of three types segments. The forward movement of the form occurs as the sprayed concrete approaches the front and of the form by removing a ring element from the rear end of the form and placing it at the front end of the form.

In this solution the ring elements are not supported. It also appears to be a relatively complicated and a time consuming process to demount the ring elements, move them forward and put them together again. It has not been explained how the demounting and the mounting occurs.

NO 122758 describes a method for production of constructions such as sealing vault or walls by which a cloth is stretched out and make a form for a concrete construction. To make the cloth stiffer, concrete is sprayed on it. The sprayed concrete is allowed to solidify slightly before the construction carrying mass is added to the form. The cloth shall remain on the tunnel lining after hardening of the concrete and it has therefore the object to be a part of the tunnel lining.

Contrary to the above described solutions, a method and an apparatus has been developed by the present invention where the friction between the slip form and a concrete construction is reduced substantially so that it is possible to build concrete constructions in a cost efficient way. Short summary of the invention

A method and an apparatus for continuous forming of a concrete construction, such as a lining for a tunnel or a OJ ω t t

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mechanism in this case is teethed wheels with corresponding tooth rod rails. Figure 5 shows a detail of the apparatus according to the invention with a concrete sprayer. Figure 6 shows a detail of slide steering for a concrete sprayer. Figure 7 is a schematically section of a tunnel where an enclosure has been established and which shows how the forming process can proceed in the starting phase, here in a variant where the isolation is an outer form, a membrane is fed mechanically and where the rock surface has been regulated. Figure 8 is a schematically section resembling figure 7 but here the isolation or a combination of isolation and a membrane has been arranged directly against a regulated rock surface. Figure 9 is a schematically section of a tunnel which shows the forming process as it is carried out. In this case the rock surface has been regulated, a membrane has been put on the regulated rock surface and the foil is fed out from a roll of the formwork trolley. Figure 10 is a schematic section compared to figure 9 but here the membrane is sprayed against the regulated rock surface.

Figure 11 is a schematic section similar figure 9 and 10 but here an isolation between the membrane and the concrete lining has also been put in. Figure 12 shows very schematically an embodiment of the invention with hydraulic forward pulling mechanism, where the apparatus is arranged on rails, and where steering rails have been arranged for further steerable movement . Figure 13 shows a very simple example of how the apparatus according to the invention is adapted to slide along a stand-alone wall when moulding is carried out.

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aluminium foil, paper or some other material having suitable properties .

The foil 10 may be arranged by means of suitable means. This occurs preferably continuously but also stepwise. In one embodiment of the invention the foil 10 is fed out in front of the formwork trolley 5. Feeding out may in a preferred embodiment of the invention occur from a roll 22 on the formwork trolley 5.

The surface of the slip form 6 against the foil 10 can advantageously be covered by a friction reducing substance, such as a fat layer, an oil or the like. It is also correspondingly possible to apply the friction reducing agent on the surface of the foil 10 against the slip form. The friction between the foil 10 and the slip form 6 will thereby be further reduced and will facilitate the movement of the slip form 6 with ancillary formwork trolley 5 against the foil 10.

The forming process as such is illustrated in the figures 7-12. A starting phase of the forming process is shown in figures 7 and 8 and figures 9-11 show how the forming process can proceed. The formwork trolley 5 is moved forward while the concrete sprayer 16 is served and fills the form section 13 by supplying near the forward end 14 of the slip form 6. As the concrete 27 is hardened sufficiently to become self supporting the foil 10 can be removed.

It will be clear for one skilled in the art that the speed of the formwork trolley 5 and the capacity of the concrete sprayer 16 has to be adapted to the tunnel section, the form section 13, concrete thickness, concrete mixture and the length of the slip form 6 outside the spraying place. The formwork trolley 5 may preferably be moved at a speed of 0,75-1,5 m/hour, but higher speeds is of course also possible. The length of the formwork trolley 5 may vary depending on need, but a preferable length is about 2-6 meter.

If necessary the slip form 6 may be released from the concrete construction 2, 3, 18 by means of fluid supply, preferably air, via separate nozzles between the foil 10 and the slip form 6. The nozzles may in a preferred embodiment ω ) CO CO

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^

5. A preferably flexible foil 10 is arranged which substantially covers the surface 11 of the slip form 6 so that the slip form 6 can slide in relation to the foil 10 and where the foil 10 is arranged to be removed after hardening of the concrete 27, in a way corresponding to what has been described above. The formwork trolley 5 is moved forward when the concrete sprayer 16 is actuated and fills the form section 13 by supplying close to a forward end 14 of the slip form 6. The arrangement for continuous moulding of a standalone wall 18 by means of a concrete mixture and where the arrangement comprises a slip form 6 with ancillary movable formwork trolley 5 reminds in principle much of the arrangement for moulding a tunnel lining 2, 3 in a corresponding way. The slip form 6 is arranged to be carried by the formwork trolley 5 which in its turn is arranged for steerable movement along a driving direction. The arrangement also comprises means 22 for placing a preferably flexible foil 10 which substantially covers the surface 11 of the slip form 6 so that the slip form 6 can slide in relation to the foil 10 and which is arranged to be removed after hardening of the concrete 27.

The method and apparatus according to the invention can advantageously be used for rehabilitation of existing constructions including stone walls, old cement and concrete linings and nets for stone protection.

Claims

C l a i m s

1. Method for continuous forming of a concrete construction such as a lining for a tunnel or a subpassage (2, 3) by means of a concrete mixture and a slip form (6) with ancillary formwork trolley (5) , characterised in that it comprises the following steps : the slip form (6) with ancillary formwork trolley (5) is arranged for steerable movement along the tunnel, an end closure (12) which is anchored in the tunnel is established, at least one concrete sprayer (16) is attached to the slip form (6) with ancillary formwork trolley (5) , a preferably flexible foil (10) , which substantially covers the surface (11) of the slip form (6) is arranged so that the slip form (6) can slide in relation to the foil (10) and where the foil (10) is arranged to be removed after hardening of the concrete (27) , and the formwork trolley (5) is moved forward while the concrete sprayer (16) is actuated and fills the form section (13) by supplying close to the forward end (14) of the slip form (6) .

2. Method according to claim 1, where the slip form (6) and/or the surface of the foil (10) is covered by a friction reducing agent, such as a grease layer or the like.

3. Method according to any of the preceding claims, in which a support (4) along the tunnel for the slip form (6) with ancillary formwork trolley (5) is established.

4. Method according claim 3, in which the slip form (6) with ancillary formwork trolley (5) is arranged on rails (8) carried by the support (4) along the tunnel in the said steerable movement.

5. Method according to any of the preceding claims, in which at least one steering rail (7) is arranged to guide the slip form (6) with ancillary formwork trolley (5) in the said steerable movement is attached to the tunnel wall .

6. Method according to any of the preceding claims, in which a membrane (15) for covering the top side of the tunnel lining is arranged.

7. Method according to any of the preceding claims, in which the foil (10) and/or the membrane (5) is fed out continuously in front of the slip form (6) .

8. Method according to any of the preceding claims, in which long fibres as a sole or a part of reinforcement is integrated in the concrete mixture.

9. Method according to any of the preceding claims, in which the long fibres have a length of at least 50 mm.

10. Method according to any of the preceding claims, in which the concrete mixture which is used is a general spraying concrete mixture which comprises Portland cement, sand, water and super plastisisers.

11. Method according to any of the preceding claims, in which a non-alkali accelerator is added to the concrete mixture .

12. Method according to any of the preceding claims, in which sliding agent, air, water and additives are supplied to the concrete sprayer (16) through separate and/or common connections (19) .

13. Method according to any of the preceding claims, in which the concrete sprayer (16) is steerable and movable.

14. Method according to any of the preceding claims, in which the concrete sprayer (16) is moved sidewardly by means of cross running slides (9) , roller feeding, chain feeding and/or tooth feeding.

15. Method according to any of the preceding claims, in the case of a double sided slip form (9) where isolation

(17) is arranged as an outer form (6a) in the slip form (6) .

16. Method according to any of the preceding claims, in which isolation (17) with suitable fastening means for continuous supplying and placing during spraying of the concrete mixture.

17. Method according to any of the preceding claims,_ in which the slip form (6) is released from the concrete constructions by means of fluid addition, preferably air, via nozzles between the foil (10) and the slip form (6) and where the nozzles are arranged along the section of the inner form (6b) .

18. Method for continuous forming of a stand-alone wall

(18) by means of a concrete mixture and a slip form (6) with ancillary formwork trolley (5) characterised in that it comprises the following steps : the slip form (6) with ancillary formwork trolley (5) is arranged for steerable movement along a driving direction, an end closure (12) is established as a base for the moulding, at least one concrete sprayer is fastened to this slip form (6) with ancillary formwork trolley (5) , a preferably flexible foil (10) which substantially covers the surface (11) of the slip form (6) is arranged so that the slip form (6) can slide in relation to the foil (10) , and where the foil (10) is arranged to be removed after hardening of the concrete (27) , and the formwork trolley (5) is moved forward while the concrete sprayer (16) is actuated and fills the form section (13) through supplying close to a forward end (14) of the slip form (6) .

19. Apparatus for continuous forming of a concrete construction such as a tunnel lining or a subpassage (2, 3), by means of a concrete mixture and where the apparatus comprises a slip form (6) with ancillary movable formwork trolley (5) , characterised in that the slip form (6) is arranged to be supported of the formwork trolley (5) which in its turn is arranged for steerable movement along the tunnel or the subpassage (2,3), and means for arranging a preferably flexible foil (10) which substantially covers the surface (11) of the slip form (6) so that the slip form (6) can slide in relation to the foil (10) and which is arranged to be removed after hardening of the concrete (27) .

20. Apparatus claim 19, in which the surface of the slip form (6) and/or the foil (10) comprises a friction reducing agent such as a grease layer or the like.

21. Apparatus according to any of the claims 19-20, in which the formwork trolley (5) is arranged for guidance in the said steerable movement along rails (8) on a support (4) in the tunnel .

22. Apparatus according to any of the claims 19-21, in which the formwork trolley (5) is arranged for guidance in the said steerable movement along at least one steering rail fastened to the tunnel wall (1) .

23. Apparatus according to any of the claims 19-22, in which pulling of the formwork trolley (5) occurs by means of tooth wheel (25) and corresponding tooth rod rails (26) .

24. Arrangement according to any of the claims 19-23, in which the slip form (6) with ancillary formwork trolley (5) comprises at least one concrete sprayer (16) with several connections (19) for concrete, air and additives and with a mouth preferably at a small distance in on the slip form (6) calculated from the forward end (14) of the slip form (6) .

25. Arrangement according to claim 24, where the concrete sprayer (16) is steerable and movable.

26. Arrangement according to claim 25, where the concrete sprayer (16) is arranged for movement by means of cross running slide guidance (9) , roller feeding, chain feeding and/or tooth feeding.

27. Apparatus according to any of the claims 19-26, in which the slip form (6) is single sided.

28. Apparatus according to any of the claims 19-27, in which the slip form (6) is double sided.

29. Apparatus according to any of the claims 19-28, in which the slip form (6) is a combination of a single and double sided form, preferably double sided in vertical and nearly vertical wall parts and single sided in horizontal and nearly horizontal sealing (parts) .

30. Apparatus according to claims 28-29, in which the isolation (17) is an outer form (6a) of the slip form (6) .

31. Apparatus according to any of the preceding claims, in which the foil (10) and/or the isolation (17) is arranged to be fed out from rolls (22) on the formwork trolley (5) .

32. Apparatus for continuous forming of a stand-alone wall (18) by means of a concrete mixture and where the apparatus comprises a slip form (6) with ancillary movable formwork trolley (5) , characterised in that the slip form (6) is arranged to be carried by the formwork trolley (5) , which in its turn is arranged for steerable movement along a driving direction, and means (22) for arranging a preferably flexible foil (10) which substantially covers the surface (11) of the slip form (6) so that the slip form (6) can slide in relation to the foil (10) , and which is arranged to be removed after hardening of the concrete (27) .