WO2016183645A1

WO2016183645A1 - Tunnel treatment method and device with self-lined and self-injectable pipe-roofing

Info

Publication number: WO2016183645A1
Application number: PCT/BR2015/000072
Authority: WO
Inventors: Márcio DOS SANTOS
Original assignee: Dos Santos Márcio
Priority date: 2015-05-15
Filing date: 2015-05-15
Publication date: 2016-11-24
Also published as: BR112016023275A2; BR112016023275B1

Abstract

The subject matter of the present patent allows soil or rock masses to be drilled by rotary percussion drilling using the HIDROBIT® (1) coupled to the casing shoe (2), at the same time as cement grout is injected with the reinforcement, by simultaneous introduction of the Schedule steel pipe or the like, which is previously screwed (and optionally welded) into the casing shoe, remaining in the bore hole after cement grout is injected. The HIDROBIT® (1) is recoverable and is therefore withdrawn from the bore hole after drilling, reinforcement and injection, which are simultaneously carried out when producing the self-lined and self-injectable pipe-roofing in a single operation. With the present method, once drilling is completed, reinforcement is also completed in that the Schedule pipe or the like is inserted and cement grout is injected, since these operations are simultaneously carried out during the drilling step, in other words pipe-roofing is completed and the entire work is finished in a single operation with the withdrawal of the recoverable HIDROBIT® (1) tool by reversing the rotary movement of the drill, uncoupling the HIDROBIT® from the casing shoe (2) screwed (and optionally welded) into the Schedule steel tube or the like that is used as a reinforcement for the self-lined and self-injectable pipe-roofing.

Description

PROCESS AND DEVICE FOR TREATMENT OF TUNNELS THROUGH SELF-COATED AND SELF-INJECTABLE TUBULAR ROWS.

Patent Cams

Reduction of treatment execution time for tunnel support; Reduction of costs with materials and labor, employed in the execution of treatment to sustain tunnels;

Applicability for the treatment of tunnels, execution of special foundations, consolidations and massive containment, allowing the reduction of time and costs with materials and labor applied in these services, as well as providing greater sustainability, versatility, technical accuracy and safety.

State of the Art

Tunnel drilling is a challenge facing humanity for many centuries. These are relatively expensive and time consuming works, as they require studies, several technologies and complex executive processes that are dimensioned according to variables such as: application, dimensions and mainly geotechnical geological characteristics of the massif to be traversed, but the economic and social benefits are numerous. Tunnels have become a milestone in the development of civilizations and empires, as in ancient Rome through the implementation of tunnels and water supply passages, freight transport and access between cities, enabling the expansion of urban borders and territories.

Today is no different, with increasing population density in large urban centers as well as the advancement of globalized trade relations, in many cases tunnels are the only solution to connect two regions and thus enable the flow of people, commerce and services.

In Brazil, the applicability of tunnels is also essential to mitigate environmental impacts that would be caused by the opening of roads in mountainous regions. The main links between Planalto Paulista and the coast of the state of São Paulo are through the tunnels of the Imigrantes and Anchieta highways. Also with the duplication of Rodovia dos Tamoios, a project that is underway, it is intended to lessen the impact of the work on the Serra do Mar State Park by running more than half of the highway section in tunnels.

The tunnels are presented not only as a solution for subway works but also as an excellent solution for social mobility in the cities of São Paulo, Rio de Janeiro, Belo Horizonte, Fortaleza and Salvador, like the big cities like London and New York, but also as a solution. For road works as in the case of the North Ring Road in Serra da Cantareira (SP), New Ascent of Serra de Petrópolis (RJ), Via Expressa and Binary to replace the Perimetral Via in the Port Zone of Rio de Janeiro (RJ), also apply to railway works such as the North & South Railway, Dams and Hydroelectric Dams, Pipelines, among other applications.

The executive processes involved in tunneling have evolved over time. The Subalpine Tunnel in Switzerland, the 50.5km Eurotunnel submerged beneath the English Channel, linking France with England, considered one of the most important engineering works in the world, are examples of the advancement of technology and methodology employed in the execution of tunnels.

Today there are basically two methods used for tunneling, the TBM (Tunnel Boring Machine) which uses large equipment (tunneling machines) that automatically drill the mass, excavate and remove the material and finally stabilize the vault. and rods with the installation of reinforced concrete staves. The second is the New Austrian Tunneling Method (NATM) (Ladislaus von Rabcewicz, Leopold Muller, and Franz Pacher, 1962, Austria) which unites a set of stabilization and excavation techniques for tunnel advancement.

The most common technique of treatment and stabilization of the rock for advancing tunnel excavation is the use of Injected Tubing. This technique consists of performing a series of perforations tangent to the contour of the tunnels to be excavated. They are thus performed with positive inclination towards the tunnel, especially concentrated in the tunnel ceiling for its complete stabilization, allowing the excavation of the tunnel.

Thus, the current state of the art is known for the following technologies:

Traditional Filing (Injected Tubular Filing)

This process is performed in three operations:

1 ^to drilling with 4 to 5 inch diameter (100 to 125mm);

2 steel tube insertion Schedule manchetado or similar, with a nominal diameter of 2½ inch (62,68mm internal and external 73mm), being the most usual for this kind of treatment in Brazil;

3 ^a Cement grout injection through the headline valves with pressures normally ranging from 5kgf / cm ² to 30kgf / cm ² , which are calculated and specified by the designer according to the geological-geotechnical conditions of the mass to be treated, in addition to experience of the performing companies.

Jet grouting

This is a methodology that is already used worldwide. It consists of the technique of mass improvement with grout injections at high pressures (usually from 200kgf / cm ² to 500kgf / cm ² ). From this main concept come three methods applied depending on the type of mass and diameter of the soil cement column to be executed, they are:

1 ^to CCP (Cement Churning Pile) with single-rod drilling and injection (Monotube) (NAKANISHI, 1970, Japan). With this method it is possible to make cement soil columns up to 80cm in diameter using only the high pressure of the grout injection pump without the application of compressed air.

2 ^to JSG (Jumbo Special Grout) or JG (Jumbo Grout) (Nakanishi and Yahiro, 1970, Japan), widely used in Brazil. In this method two coaxial rods are used, where in the inner rod the cement grout is injected high pressure and compressed air in the external rod in order to give greater kinetic energy to the grout jet and thus obtain columns of cement soil with diameters above 80cm, usually up to 2m in diameter.

3 ^to CJG (Columm Jet Grout), with triple tube or rod, using compressed air (Yahiro, 1976, Japan). The latter is not widely used in Brazil.

All these processes that make up Jet Grouting consist of soil erosion (erosive process), using high pressures applied to the soil formation of cement columns, therefore more susceptible to significant repression depending on the geological-geotechnical conditions of the massif where will run the tunnel, especially the low coverage.

The state of the art of this process consists of two or three operations: 1 ^a 4 to 5 inch (100 to 125 mm) diameter Drill through drill rods and triconic drills;

2 ^a high-pressure cement grout injection (200 kgf / cm ² to 500 kgf / cm ² ); 3 ^a Newly injected column frame by inserting Schedule steel tube or similar. (Optional step, its use is determined by the designer, according to the geological-geotechnical conditions of the massif). Following these advances, a technology that corresponds to the current state of the art has been developed where these methodologies have been reduced from three operations to two operations, called Self-Piercing Filing.

In this methodology the partial drilling with a pilot bit coupled to a drilling shoe that advances with a steel tube with headline valves in its extension is executed. This steel tube is welded to the shoe that is coupled to the pilot bit. This set advances concurrently in drilling operation.

When the design-determined depth is reached, the rotational motion of the drill is reversed, causing the pilot bit to unlock from the lost tube and shoe assembly, and so is pulled out of the hole, leaving the steel tube and shoe in the hole.

Thereafter, the steel pipe is plugged into the borehole to inject grout through the headline valves installed along the steel pipe or in some cases a shutter is inserted into the steel pipe to perform the injection of cement grout in a partial way (in different horizons) isolating different headlines.

Thus, this current state of the art has reduced the methodologies prior to two operations. For this, each threading performed must absorb the cost of a new special shoe that remains lost in the hole near the steel tube.

This technology, which represents the most advanced state of the art is described in patent WO2009007494, BIT ASSEMBLY owned by Robit Rocktools LTD.

While this methodology saves time and labor over traditional methodologies, it generates high material costs for the special shoe that is lost in each hole, as well as the additional cost involved in providing larger diameter steel tubes. in relation to the one used in the traditional lines, which represents an increase in the cost of manufacture and importation since the offered steel tube is not produced in Brazil. When this cost is multiplied by the number of tubular lines performed at each tunnel excavation advance, and multiplied over the many kilometers of tunnel it is intended to perform, it is quite costly compared to traditional methodologies.

The holder of the present patent, through experience gained over 27 years running tunnel treatment, introduces a new Tunnel Treatment Process and Device through the execution of Self-Coated and Self-Injectable Tubular Filings in a single operation. 15 000072

6th

for the stabilization of tunnel vaults and rods in a single operation, including:

1. drilling in the massif,

2. The frame by the introduction of Schedule steel pipe or similar.e 3. The injection of cement grout.

The three phases in one step, providing time savings, lower cost and greater security. They are achievable in any type of soil, with horizontal, vertical and inclined perforations, allowing them to be applicable to a range of services in addition to injected tubular lines for tunnel treatment, as well as special foundations, solidification, retaining and other related.

Advances to the State of the Art brought by the Process and Device for Tunnel Treatment through the execution of Self-lining and Self-Injecting Tubular Filings, object of this patent.

The technology presented in this new process and device was made possible with the creation and development of the HIDROBIT ^® tool, described above, which is coupled to a new Drilling Shoe, thus allowing these treatments to be performed in a single operation with greater safety, less lead time, reduced operating costs, better drilling quality with greater tilt assurance and better control of the parameters used for grouting or other stabilizing fluids, thus avoiding unwanted setbacks, especially in low-coverage tunnels.

The Tunnel Treatment Process and Device through the Self-Coated and Self-Injecting Tubular Filings applied to the tunnel treatment is performed in a single operation, that is, drilling is performed with Schedule steel pipe or similarly, concomitantly with grout injection according to controlled pressures and as determined by the designer, from low to high pressures, with better grout volume control. Therefore, as the mass is treated by injection of grout, It makes the frame by inserting the Schedule steel pipe or similar, minimizing the deformation of the massif and consequent superficial repressions in materials with any geological-geotechnical characteristics.

The existing methodologies in the national and international market for Tubular Filings contemplate the partial drilling, that is, they use steel rods and tubes sectioned in shorter lengths and that are coupled during the drilling until the pre-established length is reached. in project. Unlike these methodologies, the new Tunnel Handling Process and Device through Self-Coated and Self-Injecting Tubular Filings is pierced in a single step using a single flight of rods and steel tubing sized according to the final length of the Filing, usually between 12 and 15m, therefore, the maximum straightness is obtained, ensuring the minimum deviation because it is a structure that gives greater rigidity to the set, at the same time as injection, which with better volume and pressure controlled through the innovative Special Nozzle Nozzle, can offer greater assurance of full injection of threading over the perforated horizon, thus also avoiding random dispersion of the grout.

The creation of HIDROBIT ^® , coupled with an innovative Drilling Shoe has enabled the development of this new patent, entitled Tunnel Treatment Process and Device through the execution of Self-Coated and Self-Injectable Tubular Filings and has advanced the State of the Art. The innovations described below are the set for coated drilling and grout injection, consisting of: o HIDROBIT ^® : Tool in elongated cylindrical shape, developed in special steel for drilling in soils, rocks, rock blocks, boulders, and materials with SPT 50 blows or high rock consistency.

It is internally coupled to the Drill Shoe through a self-locking system that transmits the rotational motion of the drill and rotopercussive impact through the Top Hammer or DTH (Down The Hole Hammer) bottom hammer to the joint, thus allowing simultaneous drilling and grout injection to advance. This self-locking system also allows HIDROBIT ^{® to} be retrievable, ie it is withdrawn upon completion of the already drilled, armed and injected tubing for use on other injected tubing.

It has two front holes that allow the passage of stabilizing fluid and / or compressed air used in drilling. It also has a side orifice for fitting the Injector Nozzle, through which the grout is injected simultaneously to the perforation, which is internally valved for directing the fluid.

Punching Shoe: Ring-shaped piercing element by which the HIDROBIT ^® is coupled. Also developed in special steel for drilling in soils, rocks, rock blocks, boulders, and materials with SPT> 50 blows or high rock consistency.

It is coupled externally to HIDROBIT® via the self-locking system described above.

The Drill Shoe has a special rotary system consisting of a fixed part that allows free rotation of the shoe. This fixed part is threaded (can also be welded) to the Schedule or similar steel pipe, which will serve as a frame for the Filing. By advancing the drilling, the Shoe carries the Schedule or similar steel pipe, inserting it internally into the bore during simultaneous injection of grout.

It has a separating channel between the fixed and movable part, through which allows the passage of the cement grout from the Special Injector Nozzle;

Special Injector Nozzle: Element that directs the flow of injection of radial grout to the perforation and can be directed with varying inclinations, pressures, volumes and velocity. It was developed in steel special to withstand low to high pressures and has a shape that allows uniform injection of the perforated section by the HIDROBIT ^® set and Punch Shoe. This is coupled to the lateral HIDROBIT® office, through which the cement grout is injected radially taking advantage of the rotation movement of the perforation, performing the injection concomitantly with the perforation.

Illustrations and Description of the Process and Device for Tunnel Treatment through Self-Coating and Self-Injecting Tubular Filings, object of this patent.

In order to have a proper view of the new device and an understanding of the process of use, the illustrative figures of the HIDROBIT ^® and Punch Shoe set are attached as follows:

Figure 1: Side View of the Set;

Figure 2: Top View of the Set (Injector Nozzle Detail);

Figure 3: Front View of the Assembly;

Figure 4: Posterior View of the Set;

Figure 5: Side View of HIDROBIT ^® ;

Figure 6: Bottom View of HIDROBIT ^® (Self-Locking System Detail); Figure 7 is a perspective sectional view of the recoverable HIDROBIT ^® tool set and drill shoe.

The new device is basically made up of two parts, one internal, recoverable HIDROBIT ^® tool (1) and one external, drill shoe (2), which work together, being joined by means of a self-locking device (6).

The recoverable HIDROBIT ^® tool (1) is composed of a cylindrical elongated body that has an internal channel (5) for fluid passage, a nozzle (3) located on the side, through which the injection of grout is performed. of cement. It also has two front holes (4) for drilling fluid outlet, and two side grooves (8) for leaving excess volume of reflux material from drilling and injection. The drilling shoe (2) is an annular shaped body and surrounds the recoverable HIDROBIT ^® tool (1), both of which are integrally coupled. The drilling shoe (2) has a rotating body spaced by a channel (7) that allows fluid to escape from the special nozzle. Just above is a fixed part that is threaded (can be welded) to the Schedule or similar steel pipe that will serve as a frame for the casting. A specially developed nozzle designed and manufactured in special steel to withstand low to high pressures (5 kgf / cm ² to 500 kgf / cm ² ) is also designed, which is coupled to the side hole (3) of HIDROBIT ^® (recoverable tool) where the cement grout is injected radially or inclined.

The object of the present invention allows the rotopercussive drilling in the tunnel mass, in soil or rock, from the rotation and percussion of the HIDROBIT® coupled to the Drilling Shoe, performed simultaneously to the injection of cement grout with the frame through the concomitant introduction of the Schedule or similar steel pipe, which is previously threaded (can be welded) to the Drill Shoe that remain in the hole after grout injection. HIDROBIT ^® is recoverable, so it is withdrawn from the bore after simultaneous drilling, arming and injection when performing Self-Coating and Self-Injecting Tubular Filings in a single operation.

With the present process, when the drilling is completed, the frame will be automatically completed by inserting Schedule or similar tube as well as the injection, since they are executed simultaneously during the drilling stage, that is, the drilling will be completed, completing all the drilling. work in a single operation by removing the recoverable HIDROBIT ^® tool (1) by decoupling it from the drill shoe (2) that is welded or threaded to the steel tube from the reversal of the rotational motion of the drill.

Results By performing Coated Drilling and Cement Grout Injection in a single operation through the new Process and Device for Tunnel Treatment through Self-Coated and Self-Injectable Tubular Filings, we obtain technical and financial benefits, which are listed below:

· Safety: Because it is performed in a single operation, which includes: Drilling, Schedule or similar steel pipe frame, and grout injection, the solid mass is instantaneously treated ensuring its structural stability, minimizing the risk of deformation and setbacks from exposure to perforations that are not rapidly armed and injected.

• Technical Precision: The composition of materials used in the set combined with its shape, gives the drilling a greater guarantee of the slope, because the structure acquires greater rigidity compared to traditional methodologies, thus reducing deviations from the predetermined slope in design.

• Execution Time: A gain of at least 50% of time is obtained compared to current methodologies (national or international), mainly by reducing the executive process to a single operation.

· Parameter Control: In this new process and device it is possible to control more precisely and safely the parameters of pressure, volume and time of grout injection, ensuring the integral injection of the treated horizon and also avoiding the random dispersion of grout. in any geological-geotechnical formation.

· The Effective Diameter of Self-Coating and Self-Injecting Tubular Filings performed through this new Process and Device, which typically ranges from 20cm to 60cm, is determined by the characteristics of the soil mass and / or rock mass to be treated. From these geological-geotechnical characteristics, the parameters for grout injection, such as pressure, volume, speed among others, which will result in the Effective Diameter obtained in the execution of the Filings.

• Low Coverage Tunnels: Precision Injection Parameter Control allows for varying the pressure and volume of grout over the horizon to be treated according to the geological-geotechnical features of the massif, thus achieving better control. these parameters in certain sections of the massif, thus minimizing surface settlements, which are more susceptible in low coverage tunnels.

· Cost Reduction: The entire innovative HIDROBIT ^® Drilling, Armature and Injection set, developed by the Process and Device for Tunnel Treatment through Self-Coated and Self-Injectable Tubular Filings in a single operation, had their studies based on operating with Schedule or similar steel pipe with nominal diameter 2 ½ inches (73mm outside and 62.68mm inside), ie, within the standard used in most tunnel treatments through Injected Tubular Filings in Brazil, and reduced operating costs involving labor and additional accessories used in injection and runtime. In the methodologies currently available in the national and international market, it is necessary a team to handle and change tooling for the execution of grout injections, as well as the preparation and operation team of the injection pump. HIDROBIT ^® eliminates the change of tooling used in the injection of cement grout, as it is performed simultaneously with drilling and reinforcement. · Versatility in Application: Breaking the paradigm of the applicability of certain tools and methodologies restricted to specific drilling rigs, HIDROBIT ^® is designed to work in conjunction with hydraulic and pneumatic drilling rigs, with top hammers or hammers. Down The Hole Hammer (DTH) couplings coupled to hydraulic rotors or tires. HIDROBIT is also designed to work on medium to high torque specific Hydraulic Drills, thus extending the application range of HIDROBIT ^® with larger diameters if required by using steel tubes with nominal diameter over 2 ½ inches for tunnel treatment. The system can also be used in Drilling Jumps, but due to the torque limitation of this type of equipment, the drilling system should also be limited to smaller diameters and depths than those applicable to Medium to High Torque Hydraulic Drills. tunnel treatment.

Claims

1. TUNNEL TREATMENT PROCESS AND DEVICE THROUGH SELF-COATED AND SELF-INJECTABLE TUBULAR ROWS, for simultaneous coated drilling and grout injection, which reduces the drilling, framing and injection steps to a single operation, drilling in solid, the frame by the introduction of Schedule or similar steel pipe and the injection of grout, characterized by having a recoverable HIDROBIT ^® tool (1) that has elongated cylindrical shape that has internal channel (5) for passage of fluid and a special nozzle (3) for radial outlet of the grout. It also has a self-locking system (6) for coupling the parts and retrieving them, as well as two front holes (4) for stabilizing fluid and / or compressed air used for drilling, and two lateral grooves (8) for Excess volume of backflow material from drilling and injection, which if required, is supplemented by the use of check valves in the borehole.

2. PROCESS AND DEVICE FOR TREATING TUNNELS THROUGH SELF-COATED AND SELF-INJECTABLE TUBULAR ROWS, according to claim 1, characterized in that it has a ring-shaped perforation shoe (2) which allows the HIDROBIT ^{® to be} enclosed. also a side hole (3) for the nozzle fitting, through which the grout is injected simultaneously to the perforation, which is internally valved for directing the fluid.

3. PROCESS AND DEVICE FOR TREATING TUNNELS THROUGH SELF-COATED AND SELF-INJECTABLE TUBULAR ROWS according to claim 1, characterized in that the perforation shoe (2) is annular in shape and has a rotary system consisting of one part. that allows the free rotation of the shoe and the fixed part is threaded (can also be welded) to the Schedule or similar steel tube, which will serve as a frame for the casting, said of the drilling shoe (2) being responsible for the advance of the drilling. where the shoe takes with you Schedule or similar steel pipe by inserting it internally into the bore during simultaneous injection of grout.

PROCESS AND DEVICE FOR TREATMENT TUNNELS THROUGH SELF-COATED AND SELF-INJECTABLE TUBULAR ROWS according to claim 3, characterized in that the drilling shoe (2) has a separating channel (7) between the fixed and movable portion. , which allows the passage of the cement grout from the nozzle Special injector, which is coupled to the lateral office (3) of the HIDROBIT ^® , through which the cement grout is injected radially taking advantage of the movement of rotation of the perforation axis, performing the injection concomitantly with the perforation and can be directed with varying inclinations, pressures, volumes and velocity.