WO2017045425A1 - 钢-混凝土复合式隧道衬砌支护结构及其制作与施工方法 - Google Patents

钢-混凝土复合式隧道衬砌支护结构及其制作与施工方法 Download PDF

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Publication number
WO2017045425A1
WO2017045425A1 PCT/CN2016/082935 CN2016082935W WO2017045425A1 WO 2017045425 A1 WO2017045425 A1 WO 2017045425A1 CN 2016082935 W CN2016082935 W CN 2016082935W WO 2017045425 A1 WO2017045425 A1 WO 2017045425A1
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plate
rib
concrete
steel plate
tunnel
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PCT/CN2016/082935
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English (en)
French (fr)
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战福军
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南京联众建设工程技术有限公司
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Publication of WO2017045425A1 publication Critical patent/WO2017045425A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D11/00—Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
    • E21D11/14—Lining predominantly with metal

Definitions

  • the invention relates to a tunnel lining supporting structure, in particular to a steel-concrete composite structure lining the road, railway, water conveying or air defense engineering tunnel, and a manufacturing and construction method thereof.
  • the tunnel lining is a permanent supporting structure constructed by steel arches and steel-concrete materials along the circumferential arch of the tunnel body to prevent deformation or collapse of surrounding rock in the tunnel.
  • Existing tunnel linings are generally provided with an initial support layer and a secondary lining layer.
  • the initial support structure consists of I-beam, arch, steel mesh, anchor and shotcrete to withstand the pressure generated by the plastic deformation of the structure above the cave after tunnel excavation to prevent deformation or collapse of the surrounding rock.
  • the tunnel shall be secondary lining.
  • the secondary lining shall be constructed by tarpaulin and concrete to form the innermost layer of the tunnel. One is used to reinforce the initial support layer; the other is to be used together with the initial support layer.
  • the initial support layer of the tunnel (ie, the primary lining layer) bears most of the load on the upper part of the cavern, but the bearing capacity of the initial support layer depends not only on the internal steel arch.
  • the frame also depends on the cooperation and support of the concrete. When the concrete is poured, it does not immediately carry the load. It requires solidification and hardening time. During this time, the support strength is not strictly guaranteed, especially in the earth's crust. In complex areas, tunnel construction collapses often occur. 2.
  • the concrete After the concrete is solidified, it is a pure rigid material, which is not easy to be deformed, non-earthquake resistant, easy to crack, easy to seep after cracking, and difficult to repair. This is a common problem after tunnel operation. 3.
  • the lining layer is too thick, generally more than 0.5 meters. When the class V is above, the surrounding rock should reach 0.7 meters or even thicker, which increases the section excavation area and the amount of excavation and extends the construction period. 4.
  • the concrete construction needs time of solidification and hardening, which affects the progress of the project. 5, the need for a dedicated large-scale initial construction trolley, equipment investment. 6.
  • Reinforcement lashing is the construction of the employer. The amount of work is large and the speed is slow.
  • the first object of the present invention is to provide a steel-concrete capable of immediately bearing pressure, collapsing, cracking resistance, strong load carrying capacity, combining primary lining and secondary lining, and repairing and strengthening the diseased tunnel.
  • the first tunnel lining support structure of the present invention is formed by assembling a unit plate with curvature along a circumferential direction and an axial direction of a tunnel hole wall; the unit plate has a pair of curved sides and a pair Straight edge, in the straight side of the cell board
  • the inner wall of the piece is spaced apart from the convex rib, the curvature of the rib is consistent with the curved edge, and a cavity cylinder is formed between the rib and the unit plate, and the surface of the rib is provided with a concrete pouring hole, and the unit corresponding to the rib
  • a concrete overflow hole is formed on the plate; at the same time, the curved edge is bent inward to form an end flange, and a side flange is arranged on the straight side.
  • the second tunnel lining supporting structure of the present invention is formed by assembling a unit plate with a curvature along a circumferential direction and an axial direction of the tunnel hole wall;
  • the unit plate has a pair of curved sides and a pair of straight sides,
  • a rib is arranged at an outer wall of the unit plate along the straight side direction, the curvature of the rib is consistent with the curved edge, and a cavity cylinder is formed between the rib and the unit plate, and the surface of the rib is provided with a concrete overflow hole a concrete pouring hole is formed on the unit plate corresponding to the rib; at the same time, the curved side is bent inward to form an end flange, and a side flange is arranged on the straight side.
  • the third tunnel lining supporting structure of the present invention is formed by assembling a unit plate with curvature along a circumferential direction and an axial direction of the tunnel hole wall;
  • the unit plate has a pair of curved sides and a pair of straight sides,
  • the unit plate extends inward to form a convex rib with a curvature, the ribs are spaced apart in a straight direction, and the arc is coincident with the curved edge, and the unit plate and the rib form a groove, and are provided for Closing the steel strip with the groove notch, forming a cavity cylinder between the sealing steel strip and the rib, and opening a concrete pouring hole on the surface of the rib, and opening a concrete overflow hole on the sealing steel strip;
  • the curved side is bent inward to form an end flange, and a side flange is provided on the straight side.
  • the fourth tunnel lining supporting structure of the invention is formed by assembling the unit plate with curvature along the circumferential direction and the axial direction of the tunnel hole wall;
  • the unit plate has a pair of curved sides and a pair of straight sides,
  • the unit plate extends outward to form a convex rib with a curvature, the ribs are spaced apart in a straight direction, and the arc is coincident with the curved edge, and the unit plate and the rib form a groove and are provided for Closing the steel strip with the groove notch, forming a cavity cylinder between the sealing steel strip and the rib, and opening a concrete pouring hole on the sealing steel strip to open a concrete overflow hole on the surface of the convex rib;
  • the curved side is bent inward to form an end flange, and a side flange is provided on the straight side.
  • an insulation layer and a metal inner liner may be sequentially added to the inner side of the tunnel on the surface of the tunnel lining support structure.
  • the manufacturing method of the first tunnel lining supporting structure of the invention comprises the following steps:
  • the main steel plate has a first pair of sides and a second pair of sides, and the first pair of sides thereof are bent upward, and a flange connecting hole is formed in the bent portion to obtain an end flange, and the second pair of edges is in the main a concrete overflow hole parallel to the first opposite side is formed on the steel plate;
  • the rib spacing is fastened to the concrete overflow hole on the inner side of the main steel plate along the second opposite side, and a cavity cylinder is formed between the rib and the main steel plate to obtain a composite steel plate;
  • the manufacturing method of the second tunnel lining supporting structure of the present invention comprises the following steps:
  • the main steel plate has a first pair of sides and a second pair of sides, and the first pair of sides thereof are bent upward, and a flange connecting hole is formed in the bent portion to obtain an end flange, and the second pair of edges is in the main a concrete pouring hole parallel to the first opposite side is arranged on the steel plate;
  • the manufacturing method of the third tunnel lining supporting structure of the invention comprises the following steps:
  • the main steel plate has a first pair of sides and a second pair of sides, and the first pair of sides is bent upward, and a flange connecting hole is formed in the bent portion to obtain an end flange, and the second side is to be main
  • the steel plate is bent upward to form spaced apart ribs, and the rib forms a groove with the main steel plate, and a concrete pouring hole is formed on the surface of the rib;
  • the fourth method for manufacturing a tunnel lining supporting structure of the present invention comprises the following steps:
  • the main steel plate has a first pair of sides and a second pair of sides, and the first pair of sides is bent upward, and a flange connecting hole is formed in the bent portion to obtain an end flange, and the second side is to be main
  • the steel plate is bent downward to form spaced apart ribs, and the rib forms a groove with the main steel plate, and a concrete overflow hole is formed on the surface of the rib;
  • the construction method of the tunnel lining supporting structure of the invention comprises assembling unit plates in the circumferential direction and the axial direction of the tunnel hole wall; wherein, in the circumferential assembly, adjacent unit plates are connected by side flanges, and the axial assembling phase The adjacent unit plates are connected by end flanges; the concrete is poured from the concrete pouring holes in the bottom-up order until the concrete fills the cavity cylinders and flows out from the concrete overflow holes, filling the tunnel wall soil layer and the unit plate The gap between the pieces can be completed.
  • the advantages of the present invention are as follows: (1) The supporting structure can immediately withstand the pressure load of the surrounding rock in the upper part of the tunnel and surrounding, and quickly and timely support the newly excavated hole body to prevent new opening.
  • the flexible structure has good seismic performance, can absorb slight deformation, and is not easy to crack.
  • the overall steel-concrete composite structure has greatly increased bearing capacity.
  • the supporting structure can be directly formed by rolling the steel plate body without weld seam.
  • the strength of the ribs constituting the arch beam is high; the support structure can be made of a full steel plate, and the seal is not easy to leak water; (5) by utilizing the principle of the concrete steel pipe, the thickness of the support structure can be greatly reduced to 0.1-0.4 m, reducing The tunnel excavation section area saves the engineering quantity and reduces the cost; because the excavation section is reduced, the span of the hole is reduced, and the stability of the hole is increased; (6) the support is a fabricated structure, and the construction speed is fast.
  • Construction worker (7) After adopting the supporting structure of the invention, the amount of concrete is reduced, and the cost is reduced; (8) The invention does not need to use a large lining trolley, thereby reducing the input of the equipment; the supporting structure is not tied by steel bars, and the utility model is omitted. A large number of labors; (9) under certain geological conditions, the back grouting process can be omitted; in cold regions, an insulating layer can be provided to prevent frost heaving damage to the supporting structure at low temperatures.
  • Figure 1 is a schematic structural view of a main steel plate of the present invention
  • Figure 2 (a) is a schematic view of a structure in which a main steel plate is bent to form a rib and an end flange (the rib is located above the plane of the main steel plate);
  • Figure 2 (b) is a cross-sectional view of Figure 2 (a);
  • Figure 2 (c) is another structural diagram of bending the main steel plate to form the rib and the end flange (the rib is located below the plane of the main steel plate);
  • Figure 2 (d) is a cross-sectional view of Figure 2 (c);
  • Figure 3 (a) is a process diagram for sealing the groove of the main steel plate groove in Figure 2 (a) by using a sealing steel strip;
  • Figure 3 (b) is a cross-sectional view of Figure 3 (a);
  • Figure 3 (c) is a process diagram for sealing the groove of the main steel plate groove in Figure 2 (c) by using a sealing steel strip;
  • Figure 3 (d) is a cross-sectional view of Figure 3 (c);
  • Figure 4 (a) is a schematic view showing the structure of the main steel plate after the plugging of Figure 3 (a);
  • Figure 4 (b) is a schematic view of the bottom structure of Figure 4 (a);
  • Figure 4 (c) is a cross-sectional view of Figure 4 (a);
  • Figure 4 (d) is a schematic view showing the structure of the main steel plate after the plugging of Figure 3 (c);
  • Figure 4 (e) is a schematic view of the bottom structure of Figure 4 (d);
  • Figure 4 (f) is a cross-sectional view of Figure 4 (d);
  • Figure 5 (a) is a schematic structural view of Figure 4 (a) after bending;
  • Figure 5 (b) is a schematic structural view of Figure 4 (d) after bending;
  • Figure 6 (a) is a schematic view showing the structure of a unit plate formed by providing a side flange on Figure 5 (a);
  • Figure 6 (b) is a schematic view showing the structure of the side flange formed on Figure 5 (b) to form another unit plate;
  • FIG. 7 is a schematic cross-sectional view showing the formation of a tunnel support structure by unit plate assembly
  • Figure 8 is a schematic cross-sectional view showing a steel-concrete composite tunnel lining supporting structure of the present invention.
  • Figure 9 (a) is a longitudinal sectional view of the steel-concrete composite tunnel lining supporting structure of the present invention.
  • Figure 9 (b) is another longitudinal sectional view of the steel-concrete composite tunnel lining support structure of the present invention.
  • Figure 10 (a) is a longitudinal sectional view of a steel-concrete composite tunnel lining supporting structure with an insulating layer;
  • Fig. 10(b) is another longitudinal sectional view showing a steel-concrete composite tunnel lining supporting structure with an insulating layer.
  • the first tunnel lining supporting structure of the invention is assembled from the unit plate 1 with curvature along the circumferential direction and the axial direction of the tunnel hole wall; when the circumferential assembly is assembled, the adjacent unit plate 1 passes the side flange 9 For connection, the adjacent unit sheets 1 are connected by the end face flange 8 in the axial assembly.
  • the unit plate 1 Since the unit plate 1 has a certain curvature, it has a pair of curved sides 2 And a pair of straight sides 3, along the straight side 3 direction on the inner wall of the unit plate 1 (ie, the inner side of the arc) is spaced apart from the convex ribs 4, the number of the ribs 4 is determined according to the actual situation, the curvature and the curved side of the rib 4 2 is uniform, or close to the arc of the curved edge, a cavity cylinder 5 is formed between the rib 4 and the unit plate 1, and a concrete pouring hole 6 is formed on the surface of the rib 4, and the unit plate 1 corresponding to the rib 4 is opened.
  • the concrete overflow hole 7 at the same time, the curved edge 2 is bent inward to form an end face flange 8, which is bent by about 90°, and the end face flange 8 is integrally formed with the unit plate piece 1 and is disposed on the straight side 3 Side flange 9.
  • the second tunnel lining supporting structure of the present invention is similar to the first structure described above, except that the rib 4 is located on the outer wall (and the outer side of the arc) of the unit panel 1, and a concrete overflow hole is formed on the surface of the rib 4 at this time. 7.
  • a concrete pouring hole 6 is formed in the unit sheet 1 corresponding to the rib 4.
  • the third tunnel lining supporting structure of the present invention is different from the above two structures, and although it is also assembled by the unit plate 1 with curvature along the circumferential direction and the axial direction of the tunnel hole wall, the unit plate 1 Having a pair of curved sides 2 and a pair of straight sides 3; but the ribs 4 are integrally formed with the unit sheets without weld seams, specifically: the unit sheets 1 extend inwardly (ie, inside the arc) to form a convex with curvature
  • the rib 4 has a plurality of cross-sectional shapes, for example, a rectangle, a trapezoid, a semicircle, a closed or a semi-closed ring, etc.; the number of the ribs 4 is determined according to the situation, and when there are a plurality of the ribs 4, The strips are spaced apart along the straight edge 3, and the arc is coincident with the curved edge 2; the unit plate 1 and the rib 4 form a groove 10, and a groove 10
  • the fourth tunnel lining supporting structure of the present invention is similar to the third structure described above, except that the rib 4 is formed by extending the unit plate 1 to the outside (ie, outside the arc), and the concrete is opened on the surface of the rib 4
  • the overflow hole 7 is provided with a concrete pouring hole 6 on the sealing steel strip 11.
  • Principle of the invention The invention simultaneously utilizes the principle of concrete steel pipe, the principle of common force of pipe and soil and the principle of prestressed concrete.
  • Principle of concrete steel pipe After the hollow steel pipe is filled with concrete, the steel pipe can exert lateral restraint on the internal compression concrete, so that the compressed concrete inside the steel pipe is always in the three-way compression state, so as to delay the internal concrete crack to the greatest extent. Produce and develop. Therefore, the compressive strength and compressive deformation resistance of the steel-concrete composite structure is significantly improved compared with the ordinary reinforced concrete structure.
  • the main body of the steel plate is made into a structure with a rib, which itself has a high moment of inertia of the section, that is, before the concrete is filled, the arch ring formed by the unit plate has already had a large circumferential bearing.
  • the compressive capacity after filling the concrete and solidifying the concrete, forms a concrete steel pipe locally.
  • the convex ribs constitute the concrete-filled steel tubular arch beam, so that the bearing capacity of the overall structure is multiplied.
  • the convex rib structure of the steel plate can be directly rolled and formed without weld seam, the strength of the arch beam is increased, the bearing capacity is enhanced, and the dynamic load can be adapted;
  • the structure is a semi-flexible structure, has good deformation resistance and is not easy to crack;
  • the thickness of the structure is thinner, which reduces the cross-sectional area of the tunnel excavation, saves the amount of excavation work, reduces the cost, and reduces the span of the hole body, thereby increasing the stability of the hole body.
  • Manufacturing method The following describes the manufacturing method of the above third supporting structure.
  • the main steel plate 1-1 is subjected to rust removal and shot peening, and the main steel plate 1-1 has a first opposite side and a second opposite side, and the first opposite side is subsequently curved into a curved side 2 . It is used to bend to form the end face flange 8, and the second pair of sides, that is, the straight side 3 described above, is used to connect the side flanges 9.
  • the main steel plate 1-1 is roll-formed after being unwound, leveled, and trimmed, and the formed main steel plate 1-1 is bent upward to form a rib 4,
  • the ribs 4 in the figure have a groove shape, the ribs 4 are spaced along the second pair of sides, and a concrete pouring hole 6 is opened on the surface of the rib 4; the first pair of sides are bent upward by about 90 degrees, and A flange connecting hole 8-1 is formed on the bent portion to obtain an end face flange 8, wherein the number and spacing of the rib, the concrete pouring hole and the flange connecting hole are set according to actual conditions;
  • the steel strips 11 after the unwinding, leveling, trimming, and opening of the concrete overflow holes 7 are arranged below the main steel plate 1-1, and the number and spacing thereof are as follows. Actual situation setting.
  • the plugged steel strip 11 is moved up to the main steel strip 1-1, preferably by welding the two contact portions together.
  • a cavity cylinder 5 is formed between the plugged steel strip 11 and the rib 4, thus obtaining a composite steel sheet.
  • the composite steel sheet formed as described above is fed into a special winding mechanism, and is bent to form a plate structure having a curvature and an inner wall having the ribs 4.
  • the side flanges 9 are welded to the straight sides 3 of the sheet structure, and the side flanges 9 are directed toward the inner side, in the same direction as the ribs 4, and the ends thereof are smoothed.
  • the contact portion of the side flange 9 with the end portion of the cavity cylinder 5 can be opened to facilitate the circulation of the concrete to be poured later, thus obtaining the unit sheet 1.
  • the fourth supporting structure is similar to the third supporting structure described above, and the difference is:
  • the formed main steel plate 1-1 is bent downward to form a rib 4, and a concrete overflow hole 7 is formed on the surface of the rib 4, as shown in Figs. 2(c) and 2(d); correspondingly in the sealing steel
  • a concrete pouring hole 6 is formed in the belt 11, as shown in Figs. 3(c) and 3(d).
  • the plugged steel strip 11 is moved down to the main steel strip 1-1, and a composite steel sheet is obtained through a series of steps.
  • the curved plate structure formed by bending, the rib 4 is located on the outer wall thereof as shown in Fig. 5(b).
  • the side flanges 9 face outward and conform to the direction of the ribs 4 as shown in Fig. 6(b).
  • the manufacturing method of the first and second support structures can be found in the invention.
  • the parameters of each part of the lining structure are determined according to the surrounding rock grade and the section size of the lining structure, including the thickness of the main steel plate 1-1, the auxiliary steel plate, the sealing steel strip 11, and the unit plate 1 Dimensions and curvature; the cross-sectional shape of the ribs 4 and the cross-sectional dimensions; the strength grade of the filled concrete 16 and the mix ratio.
  • the excavation of the surrounding rock 14 is carried out according to the tunnel lining section size. The size of the excavation surface is slightly larger than the size of the lining section. After the excavation is completed, the loose surrounding rock is removed and the early strong concrete 15 is sprayed to stabilize the inner surface of the tunnel.
  • the steel structure of the lining structure can be assembled, and the circumferential direction (ie, the circumferential direction) of the single lining plate (ie, the unit plate 1) and the axial direction are connected to the bolt through the fixing flange around the plate.
  • the connector is not limited to a bolt.
  • the unit plates (the arc radius and arc length of each type of unit plate are set according to actual conditions) are assembled into tunnel lining branches along the circumferential and axial directions of the tunnel body.
  • the unit plates of the three arc segments A, B and C are distributed along the circumferential direction of the tunnel.
  • the lining structure is fixed without significant bending and the concrete 16 is injected to fill the space between the inside of the rib 4 and the lining structure and the early strong concrete surface.
  • the concrete 16 can be blended with a certain proportion of pebbles according to the grouting equipment and the actual situation, and the particle size of the pebbles is ensured not to block the grouting equipment.
  • Grouting uses a special grouting machine for construction, and maintains a certain pressure during the grouting process to ensure the compactness of the concrete.
  • the circumferential grouting of the lining structure adopts a sequence from low to high.
  • the upper concrete overflow hole 7 begins to overflow, the lower concrete pouring hole 6 is blocked, and the concrete pouring hole 6 is continued in the upper part.
  • Pulp the interior of the rib 4 and the exterior of the structure are all filled with dense concrete throughout the structure, as shown in FIG. After the entire structure is constructed, if it is in a cold area, in order to prevent damage to the structure by low temperature, an insulating layer 12 and a metal inner liner 13 may be added.
  • the piece for connecting the insulation layer 12 is connected to the flange ring 17, and then from the heat preservation
  • the surface of the layer 12 is laid with a metal inner liner 13 on the inner side of the tunnel, and the metal inner liner 13 and the split connecting flange ring 17 are riveted with rivets, and then finished.
  • the inner lining support structure of the steel-concrete composite structural tunnel with the inner wall of the insulating layer is shown in Fig. 9(a), 9(b) and 10; wherein the insulating layer is made of materials which can be bent freely and have a certain strength. After the installation of the insulation layer is completed, the interior is modified to cover the joints of the insulation material to ensure the overall appearance.

Abstract

一种钢-混凝土复合式隧道衬砌支护结构被公开，该支护结构由带有弧度的单元板片（1）沿隧道洞壁周向和轴向拼装而成；该单元板片（1）具有一对弧形边（2）和一对直边（3），沿直边（3）方向在单元板片（1）的内壁间隔设置凸筋（4），该凸筋（4）的弧度与弧形边（2）一致，凸筋（4）与单元板片（1）之间形成空腔柱体（5），该凸筋（4）表面开设混凝土浇注孔（6），与凸筋（4）对应的单元板片（1）上开设混凝土溢出孔（7）；同时该弧形边（2）向内弯折形成端面法兰（8），并在直边（3）上设侧边法兰（9）。该支护结构能立即承受隧道上部及周边围岩的压力载荷，迅速及时支护新开挖的洞体，防止新开挖洞体坍塌；该支护结构可用于初次衬砌，也可将初次衬砌与二次衬砌合二为一，还能用于病害隧道的修复加固等。此外，该隧道衬砌支护结构的制作与施工方法也被公开。

Description

钢-混凝土复合式隧道衬砌支护结构及其制作与施工方法 技术领域
本发明涉及一种隧道衬砌支护结构，尤其涉及一种公路、铁路、输水或防空工程隧道内部衬砌的钢-混凝土复合结构及其制作与施工方法。
背景技术
隧道衬砌是为了防止隧道内围岩变形或坍塌，沿隧道洞身上部周向拱璧用钢拱架及钢-混凝土材料修筑的永久性支护结构。现有的隧道衬砌一般都设置初支护层及二次衬砌层。初支护层结构由工字钢、拱架、钢筋网、锚杆及喷射混凝土构成，用来承受隧道开挖后岩洞上方结构塑性变形产生的压力，防止围岩变形或塌落。隧道在设置初支护层后要进行二次衬砌，二次衬砌由防水布、混凝土等修筑成隧道最内层的衬砌，一是用来加固初支护层；二是与初支护层共同承受岩洞变形产生的压力；三是美化外观，线路优化，方便设置照明、通讯、排水等设施。上述结构及施工方法存在如下问题：①、一般来说，隧道的初支护层(即初次衬砌层)承受岩洞上部的大部分荷载，但初支护层的承载能力不仅取决于内部的钢拱架，还取决于混凝土的配合与支持，而混凝土浇筑时是不会立即起到承载作用的，需要凝固和硬化时间，在这段时间支护强度是得不到严格保证的，特别是在地壳复杂地带，继而会经常发生隧道工程坍塌事故。②、混凝土凝固后是纯刚性材料，不易变形、不抗震、易开裂，开裂后易渗水，并且很难修复，这是隧道运行后的通病。③、衬砌层太厚，一般都超过0.5米，在V类以上级别时，围岩要达到0.7米甚至更厚，这样就加大了断面开挖面积和工程开挖量，延长了工期。④、混凝土工程需要凝固和硬化的时间，影响工程进度。⑤、需要专用的大型初砌台车，设备投入大。⑥、钢筋绑扎是用人施工，用工量大，速度慢。
发明内容
发明目的：本发明的第一目的是提供一种能立即承载受压力、抗坍塌、抗开裂、承载能力强、可将初次衬砌与二次衬砌合二为一以及病害隧道修复加固的钢-混凝土复合式隧道衬砌支护结构；本发明的第二目的是提供该隧道衬砌支护结构的制作方法；本发明的第三目的是提供该隧道衬砌支护结构的施工方法。
技术方案：本发明的第一种隧道衬砌支护结构，由带有弧度的单元板片沿隧道洞壁周向和轴向拼装而成；所述单元板片具有一对弧形边和一对直边，沿直边方向在单元板 片的内壁间隔设置凸筋，该凸筋的弧度与弧形边一致，且凸筋与单元板片之间形成空腔柱体，所述凸筋表面开设混凝土浇注孔，与凸筋对应的单元板片上开设混凝土溢出孔；同时所述弧形边向内弯折形成端面法兰，并在直边上设侧边法兰。
本发明的第二种隧道衬砌支护结构，由带有弧度的单元板片沿隧道洞壁周向和轴向拼装而成；所述单元板片具有一对弧形边和一对直边，沿直边方向在单元板片的外壁间隔设置凸筋，该凸筋的弧度与弧形边一致，且凸筋与单元板片之间形成空腔柱体，所述凸筋表面开设混凝土溢出孔，与凸筋对应的单元板片上开设混凝土浇注孔；同时所述弧形边向内弯折形成端面法兰，并在直边上设侧边法兰。
本发明的第三种隧道衬砌支护结构，由带有弧度的单元板片沿隧道洞壁周向和轴向拼装而成；所述单元板片具有一对弧形边和一对直边，该单元板片向内侧延伸形成带有弧度的凸筋，该凸筋沿直边方向间隔分布，且其弧度与弧形边一致，所述单元板片与凸筋形成凹槽，并设有用于封堵该凹槽槽口的封堵钢带，该封堵钢带与凸筋之间形成空腔柱体，同时在凸筋表面开设混凝土浇注孔，在封堵钢带上开设混凝土溢出孔；将所述弧形边向内弯折形成端面法兰，并在直边上设侧边法兰。
本发明的第四种隧道衬砌支护结构，由带有弧度的单元板片沿隧道洞壁周向和轴向拼装而成；所述单元板片具有一对弧形边和一对直边，该单元板片向外侧延伸形成带有弧度的凸筋，该凸筋沿直边方向间隔分布，且其弧度与弧形边一致，所述单元板片与凸筋形成凹槽，并设有用于封堵该凹槽槽口的封堵钢带，该封堵钢带与凸筋之间形成空腔柱体，同时在封堵钢带上开设混凝土浇注孔，在凸筋表面开设混凝土溢出孔；将所述弧形边向内弯折形成端面法兰，并在直边上设侧边法兰。
在寒冷地区，为了防止低温对结构的破坏，可以在隧道衬砌支护结构表面向隧道内侧依次增设保温层和金属内衬层。
本发明的第一种隧道衬砌支护结构的制作方法，包括如下步骤：
(1)预备主钢板和辅助钢板；
(2)所述主钢板具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔得到端部法兰，沿第二对边在主钢板上间隔开设与第一对边相平行的混凝土溢出孔；
(3)将所述辅助钢板弯曲成截面为半闭合状的凸筋，其长度接近第一对边，并在该凸筋表面开设混凝土浇注孔；
(4)沿第二对边将所述凸筋间隔扣合在主钢板内侧的混凝土溢出孔上，凸筋与主钢板之间形成空腔柱体，得到复合型钢板；
(5)将复合型钢板弯曲成带有弧度的、内壁具有凸筋的板片结构；
(6)在所述板片结构的第二对边设侧边法兰，得到单元板片；
(7)将所述单元板片沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
本发明的第二种隧道衬砌支护结构的制作方法，包括如下步骤：
(1)预备主钢板和辅助钢板；
(2)所述主钢板具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔得到端部法兰，沿第二对边在主钢板上间隔开设与第一对边相平行的混凝土浇注孔；
(3)将所述辅助钢板弯曲成截面为半闭合状的凸筋，其长度接近第一对边，并在该凸筋表面开设混凝土溢出孔；
(4)沿第二对边将所述凸筋间隔扣合在主钢板外侧的混凝土浇注孔上，凸筋与主钢板之间形成空腔柱体，得到复合型钢板；
(5)将复合型钢板弯曲成带有弧度的、外壁具有凸筋的板片结构；
(6)在所述板片结构的第二对边设侧壁法兰，得到单元板片；
(7)将所述单元板片沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
本发明的第三种隧道衬砌支护结构的制作方法，包括如下步骤：
(1)预备主钢板和封堵钢带；
(2)所述主钢板具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔得到端部法兰，沿第二对边将主钢板向上弯折形成间隔排列的凸筋，该凸筋与主钢板形成凹槽，并在凸筋表面开设混凝土浇注孔；
(3)所述封堵钢带上开设混凝土溢出孔，将封堵钢带贴合于所述凹槽的槽口处，凸筋与封堵钢带之间形成空腔柱体，得到复合型钢板；
(4)将复合型钢板弯曲成带有弧度的、内壁具有凸筋的板片结构；
(5)在所述板片结构的第二对边设侧壁法兰，得到单元板片；
(6)将所述单元板片沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
本发明的第四种隧道衬砌支护结构的制作方法，包括如下步骤：
(1)预备主钢板和封堵钢带；
(2)所述主钢板具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔得到端部法兰，沿第二对边将主钢板向下弯折形成间隔排列的凸筋，该凸筋与主钢板形成凹槽，并在凸筋表面开设混凝土溢出孔；
(3)所述封堵钢带上开设混凝土浇注孔，将封堵钢带贴合于所述凹槽的槽口处，凸筋与封堵钢带之间形成空腔柱体，得到复合型钢板；
(4)将复合型钢板弯曲成带有弧度的、外壁具有凸筋的板片结构；
(5)在所述板片结构的第二对边设侧壁法兰，得到单元板片；
(6)将所述单元板片沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
本发明隧道衬砌支护结构的施工方法，包括沿隧道洞壁周向和轴向拼装单元板片；其中，周向拼装时相邻的单元板片通过侧边法兰连接，轴向拼装时相邻的单元板片通过端部法兰连接；按照自下而上的顺序从混凝土浇注孔内灌注混凝土，直至混凝土充满空腔柱体，并从混凝土溢出孔流出，充满隧道洞壁土层与单元板片的间隙，即可完成施工。
有益效果：与现有技术相比，本发明的优点为：(1)该支护结构能立即承受隧道上部及周边围岩的压力载荷，迅速及时支护新开挖的洞体，防止新开挖洞体坍塌；(2)该支护结构可用于初次衬砌，也可将初次衬砌与二次衬砌合二为一，还能用于病害隧道的修复加固；(3)该支护结构为半柔性结构，抗震性能好，可吸收微量变形，而且不易开裂，整体为钢-混凝土复合结构，其承载能力大大增加；(4)该支护结构可以由钢板主体直接辊压加工成型，没有焊缝，构成拱梁的凸筋强度高；该支护结构可以由全钢板制成，密封不易漏水；(5)利用了混凝土钢管原理，支护结构的厚度可以大大减薄至0.1-0.4米，减少了隧道开挖断面面积，节省了工程量，降低了造价；由于减少了开挖断面，洞体跨度减少，增加了洞体的稳固性；(6)该支护为装配式结构，施工速度快、施工工期缩短；(7)采用本发明的支护结构后，混凝土用量减少，降低造价；(8)本发明无需使用大型的衬砌台车，减少了设备的投入；该支护结构不用钢筋绑扎，省去了大量人工；(9)在特定的地质状况下，可省去背后压浆工序；在寒冷地区，可设保温层，防止低温对支护结构的冻胀破坏。
附图说明
图1为本发明主钢板的结构示意图；
图2(a)为将主钢板弯折形成凸筋和端部法兰的一种结构示意图(凸筋位于主钢板平面上方)；
图2(b)为图2(a)的截面图；
图2(c)为将主钢板弯折形成凸筋和端部法兰的另一种结构示意图(凸筋位于主钢板平面下方)；
图2(d)为图2(c)的截面图；
图3(a)为采用封堵钢带封堵图2(a)中主钢板凹槽槽口的过程图；
图3(b)为图3(a)的截面图；
图3(c)为采用封堵钢带封堵图2(c)中主钢板凹槽槽口的过程图；
图3(d)为图3(c)的截面图；
图4(a)为图3(a)封堵后主钢板的结构示意图；
图4(b)为图4(a)的底部结构示意图；
图4(c)为图4(a)的截面图；
图4(d)为图3(c)封堵后主钢板的结构示意图；
图4(e)为图4(d)的底部结构示意图；
图4(f)为图4(d)的截面图；
图5(a)为将图4(a)弯曲后的结构示意图；
图5(b)为将图4(d)弯曲后的结构示意图；
图6(a)为在图5(a)上设置侧边法兰形成一种单元板片的结构示意图；
图6(b)为在图5(b)上设置侧边法兰形成另一种单元板片的结构示意图；
图7为利用单元板片拼装形成隧道支护结构的横截面示意图；
图8为本发明钢-混凝土复合式隧道衬砌支护结构的横截面示意图；
图9(a)本发明钢-混凝土复合式隧道衬砌支护结构的纵截面示意图；
图9(b)本发明钢-混凝土复合式隧道衬砌支护结构的另一种纵截面示意图；
图10(a)为带保温层的钢-混凝土复合式隧道衬砌支护结构的纵截面示意图；
图10(b)为带保温层的钢-混凝土复合式隧道衬砌支护结构的另一种纵截面示意图。
具体实施方式
下面结合附图对本发明的技术方案作进一步说明。
本发明的第一种隧道衬砌支护结构，由带有弧度的单元板片1沿隧道洞壁周向和轴向拼装而成；周向拼装时相邻单元板片1通过侧边法兰9连接，轴向拼装时相邻单元板片1通过端面法兰8连接。由于单元板片1带有一定的弧度，所以它具有一对弧形边2 和一对直边3，沿直边3方向在单元板片1的内壁(即弧度内侧)间隔设置凸筋4，凸筋4的数量根据实际情况确定，该凸筋4的弧度与弧形边2一致，或者接近弧形边的弧度，凸筋4与单元板片1之间形成空腔柱体5，凸筋4表面开设混凝土浇注孔6，与凸筋4对应的单元板片1上开设混凝土溢出孔7；同时所述弧形边2向内弯折形成端面法兰8，弯折约90°左右，这样的端面法兰8与单元板片1一体成型，并在直边3上设侧边法兰9。
本发明的第二种隧道衬砌支护结构与上述第一种结构类似，不同之处为凸筋4位于单元板片1的外壁(及弧度外侧)，此时在凸筋4表面开设混凝土溢出孔7，与凸筋4对应的单元板片1上开设混凝土浇注孔6。
本发明的第三种隧道衬砌支护结构，与上述两种结构有所不同，它虽然也是由带有弧度的单元板片1沿隧道洞壁周向和轴向拼装而成，单元板片1具有一对弧形边2和一对直边3；但是凸筋4与单元板片一体成型，没有焊缝，具体为：单元板片1向内侧(即弧度内侧)延伸形成带有弧度的凸筋4，该凸筋4的截面形状有多种，例如有矩形、梯形、半圆形、闭合或半闭合环形等；凸筋4的数量视情况确定，当凸筋4有多个时，可沿直边3方向间隔分布，且其弧度与弧形边2一致；单元板片1与凸筋4形成凹槽10，并在该凹槽10的槽口位置设有用于封堵该槽口的封堵钢带11，该封堵钢带11与凸筋4之间形成空腔柱体5，同时在凸筋4表面开设混凝土浇注孔6，在封堵钢带11上开设混凝土溢出孔7；两个弧形边2向内弯折形成端面法兰8，并在直边3上设侧边法兰9。
本发明的第四种隧道衬砌支护结构与上述第三种结构类似，不同之处为凸筋4是由单元板片1向外侧(即弧度外侧)延伸形成，且在凸筋4表面开设混凝土溢出孔7，在封堵钢带11上开设混凝土浇注孔6。
发明原理：本发明同时利用了混凝土钢管原理、管土共同受力原理和预应力混凝土原理。混凝土钢管原理：空心的钢管在充满混凝土后，钢管可对其内部受压混凝土施加侧向约束，使钢管内部受压混凝土始终都处于三向受压状态，从而可以最大程度的延缓内部混凝土裂缝的产生和发展。因此，钢-混凝土复合结构的抗压强度和抗压缩变形的能力比普通钢筋混凝土结构有明显的提高。管土共同受力原理：闭合截面或半闭合截面的大口径管道在埋地之后，管道的上部载荷不是靠管道的刚性来承受，而是靠管道与四周土石相互作用共同承受，垂直向下的载荷就会转化为管体管壁环向的内压力。预应力混凝土原理：此种结构承受荷载之前，预先对其施加压力，使其在外荷载作用时即已经 施加了一个与外载荷方向相反的作用力。本发明中将钢板和混凝土两种材料有机的结合为一体，并充分发挥各自的特点和优势，在整体结构中分别承担不同的作用。将钢板主体制成带有凸筋的结构，其本身就已经有了很高的截面惯性矩，即在填充混凝土之前，由单元板片拼装形成的拱圈就已经具备了很大的环向承压能力，在填充混凝土且混凝土凝固后局部形成混凝土钢管，此时凸筋构成钢管混凝土拱梁，使其整体结构的承载能力更是成倍增加。由于钢板的凸筋结构可以直接辊压加工成型的没有焊缝，从而使得拱梁的强度增大，承载能力增强，能适应动载荷；该结构是半柔性结构，抗变形能力好，不易开裂；该结构的厚度较薄，减少了隧道开挖截面面积，节省了开挖工程量，降低了造价，并且洞体的跨度减小，增加了洞体的稳固性。
制作方法：下面对上述第三支护结构的制作方法作详细说明。
如图1所示，首先对主钢板1-1进行除锈、喷丸处理，该主钢板1-1具有第一对边和第二对边，第一对边后续弯曲成为弧形边2，用于弯折形成端面法兰8，第二对边即上述的直边3，用于连接侧边法兰9。
如图2(a)、2(b)所示，主钢板1-1经放卷、矫平、修边后辊压成型，成型后的主钢板1-1向上延伸弯折形成凸筋4，图示中的凸筋4的截面为槽型，凸筋4沿第二对边间隔分布，并在凸筋4表面开设混凝土浇注孔6；将第一对边均向上弯折约90度，并在弯折的部分上开设法兰连接孔8-1，得到端面法兰8，其中，凸筋、混凝土浇注孔及法兰连接孔的数量与间距按实际情况设定；
如图3(a)、3(b)所示，在主钢板1-1下方排列经过放卷、矫平、修边及开设混凝土溢出孔7后的封堵钢带11，其数量、间距按实际情况设定。
如图4(a)、4(b)、4(c)所示，将封堵钢带11上移与主钢带1-1贴合，优选是将两者接触部分焊接在一起，则在封堵钢带11与凸筋4之间形成了空腔柱体5，如此得到复合型钢板。
如图5(a)所示，将上述形成的复合型钢板送入专用卷圆机构，弯曲形成带有弧度的、内壁具有凸筋4的板片结构。
如图6(a)所示，在板片结构的直边3上焊接侧边法兰9，此时侧边法兰9朝向内侧，与凸筋4方向一致，并将其端部打磨平整，可以将侧边法兰9与空腔柱体5端部的接触部分开孔，有利于后续浇注的混凝土的流通，如此即得单元板片1。
最后，将单元板片沿隧道洞壁拼装得到支护结构。
第四种支护结构的制作方法与上述第三种支护结构类似，不同之处为：
成型后的主钢板1-1向下延伸弯折形成凸筋4，并在凸筋4表面开设混凝土溢出孔7，如图2(c)、2(d)所示；对应的在封堵钢带11上开设混凝土浇注孔6，如图3(c)、3(d)所示。如图4(d)、4(e)、4(f)所示，将封堵钢带11下移与主钢带1-1贴合，再经一系列步骤得到复合型钢板。经弯曲形成的带有弧度的板片结构，凸筋4位于其外壁上，如图5(b)所示。侧边法兰9朝向外侧，与凸筋4方向一致，如图6(b)所示。
第一、二种支护结构的制作方法参见发明内容。
施工方法：在设计方案确定后，根据围岩等级以及衬砌结构的截面尺寸确定衬砌结构的各部分参数，包括主钢板1-1、辅助钢板、封堵钢带11等厚度、单元板片1的尺寸和弧度；凸筋4的截面形状以及截面尺寸；填充混凝土16的强度等级以及配合比等。开始施工后，根据隧道衬砌断面尺寸进行围岩14的开挖施工，开挖面尺寸略大于衬砌断面尺寸，开挖完成后清除松散围岩并喷射早强混凝土15以稳固隧道内表面，待喷射混凝土初凝后即可组织拼装衬砌结构钢结构部分，单块衬砌板片(即单元板片1)的环向(即周向)和轴向通过板片四周的固定法兰与螺栓进行连接，且连接件不限于螺栓。如图7所示，在施工现场将上述制得的单元板片(各类型单元板片圆弧半径及弧长按实际情况设定)沿隧道洞身的周向和轴向拼装成隧道衬砌支护结构，图中沿隧道周向分布A、B、C三种弧段的单元板片。拼装完成后检查衬砌结构中心轴线与设计隧道中心轴线是否一致，如果存在误差，在不损伤衬砌结构的前提下，采用顶、拉等方式校正，以保证衬砌结构的轴向线性顺畅平滑，确保线性无明显折弯后固定衬砌结构并注入混凝土16填满凸筋4内部及衬砌结构和早强混凝土面之间的空间。混凝土16可以根据注浆设备和实际情况掺入一定比例的小石子，小石子的粒径以保证不堵塞注浆设备为原则。注浆使用专用的注浆机进行施工，并在注浆过程保持一定的压力，确保混凝土的密实度。在注浆过程中，衬砌结构的周向注浆采用由低到高的顺序，在上部的混凝土溢出孔7开始溢浆时，封堵下部混凝土浇注孔6，继续在上部的混凝土浇注孔6注浆。以此类推，直至整个结构中凸筋4的内部和结构外部全部由密实的混凝土充满，如图8所示。在整个结构施工完后，如果在寒冷地区，为了防止低温对结构的破坏，可加设保温层12及金属内衬层13。具体为：在支护结构的端面法兰8上(此种情况时，端面法兰可带有双排螺栓孔)安装用于铺设保温层12的分片连接法兰环17，然后再从保温层12表面向隧道内侧铺设金属内衬层13，将金属内衬层13与分片连接法兰环17用铆钉铆接，继而完 成带保温层的内壁平滑的钢-混凝土复合结构式隧道内部衬砌支护结构，如图9(a)、9(b)、10所示；其中，保温层采用可自由弯曲并具有一定强度的材料，保温层安装完成后，修饰内部，掩盖保温材料接缝，保证整体外观。

Claims (10)

  1. 一种钢-混凝土复合式隧道衬砌支护结构，其特征在于：由带有弧度的单元板片(1)沿隧道洞壁周向和轴向拼装而成；所述单元板片(1)具有一对弧形边(2)和一对直边(3)，沿直边(3)方向在单元板片(1)的内壁间隔设置凸筋(4)，该凸筋(4)的弧度与弧形边(2)一致，且凸筋(4)与单元板片(1)之间形成空腔柱体(5)，所述凸筋(4)表面开设混凝土浇注孔(6)，与凸筋(4)对应的单元板片(1)上开设混凝土溢出孔(7)；同时所述弧形边(2)向内弯折形成端面法兰(8)，并在直边(3)上设侧边法兰(9)。
  2. 一种钢-混凝土复合式隧道衬砌支护结构，其特征在于：由带有弧度的单元板片(1)沿隧道洞壁周向和轴向拼装而成；所述单元板片(1)具有一对弧形边(2)和一对直边(3)，沿直边(3)方向在单元板片(1)的外壁间隔设置凸筋(4)，该凸筋(4)的弧度与弧形边(2)一致，且凸筋(4)与单元板片(1)之间形成空腔柱体(5)，所述凸筋(4)表面开设混凝土溢出孔(7)，与凸筋(4)对应的单元板片(1)上开设混凝土浇注孔(6)；同时所述弧形边(2)向内弯折形成端面法兰(8)，并在直边(3)上设侧边法兰(9)。
  3. 一种钢-混凝土复合式隧道衬砌支护结构，其特征在于：由带有弧度的单元板片(1)沿隧道洞壁周向和轴向拼装而成；所述单元板片(1)具有一对弧形边(2)和一对直边(3)，该单元板片(1)向内侧延伸形成带有弧度的凸筋(4)，该凸筋(4)沿直边(3)方向间隔分布，且其弧度与弧形边(2)一致，所述单元板片(1)与凸筋(4)形成凹槽(10)，并设有用于封堵该凹槽(10)槽口的封堵钢带(11)，该封堵钢带(11)与凸筋(4)之间形成空腔柱体(5)，同时在凸筋(4)表面开设混凝土浇注孔(6)，在封堵钢带(11)上开设混凝土溢出孔(7)；将所述弧形边(2)向内弯折形成端面法兰(8)，并在直边(3)上设侧边法兰(9)。
  4. 一种钢-混凝土复合式隧道衬砌支护结构，其特征在于：由带有弧度的单元板片(1)沿隧道洞壁周向和轴向拼装而成；所述单元板片(1)具有一对弧形边(2)和一对直边(3)，该单元板片(1)向外侧延伸形成带有弧度的凸筋(4)，该凸筋(4)沿直边(3)方向间隔分布，且其弧度与弧形边(2)一致，所述单元板片(1)与凸筋(4)形成凹槽(10)，并设有用于封堵该凹槽(10)槽口的封堵钢带(11)，该封堵钢带(11)与凸筋(4)之间形成空腔柱体(5)，同时在封堵钢带(11)上开设混凝土浇注孔(6)，在凸筋(4)表面开设混凝土溢出孔(7)；将所述弧形边(2)向内弯折形成端面法兰(8)， 并在直边(3)上设侧边法兰(9)。
  5. 根据权利要求1-4任一所述钢-混凝土复合式隧道衬砌支护结构，其特征在于：在隧道衬砌支护结构表面向隧道内侧依次增设保温层(12)和金属内衬层(13)。
  6. 根据权利要求1所述钢-混凝土复合式隧道衬砌支护结构的制作方法，其特征在于包括如下步骤：
    (1)预备主钢板(1-1)和辅助钢板；
    (2)所述主钢板(1-1)具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔(8-1)得到端部法兰(8)，沿第二对边在主钢板(1-1)上间隔开设与第一对边相平行的混凝土溢出孔(7)；
    (3)将所述辅助钢板弯曲成截面为半闭合状的凸筋(4)，其长度接近第一对边，并在该凸筋(4)表面开设混凝土浇注孔(6)；
    (4)沿第二对边将所述凸筋(4)间隔扣合在主钢板(1-1)内侧的混凝土溢出孔(7)上，凸筋(4)与主钢板(1-1)之间形成空腔柱体(5)，得到复合型钢板；
    (5)将复合型钢板弯曲成带有弧度的、内壁具有凸筋(4)的板片结构；
    (6)在所述板片结构的第二对边设侧边法兰(9)，得到单元板片(1)；
    (7)将所述单元板片(1)沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
  7. 根据权利要求2所述钢-混凝土复合式隧道衬砌支护结构的制作方法，其特征在于包括如下步骤：
    (1)预备主钢板(1-1)和辅助钢板；
    (2)所述主钢板(1-1)具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔(8-1)得到端部法兰(8)，沿第二对边在主钢板(1-1)上间隔开设与第一对边相平行的混凝土浇注孔(6)；
    (3)将所述辅助钢板弯曲成截面为半闭合状的凸筋(4)，其长度接近第一对边，并在该凸筋(4)表面开设混凝土溢出孔(7)；
    (4)沿第二对边将所述凸筋(4)间隔扣合在主钢板(1-1)外侧的混凝土浇注孔(6)上，凸筋(4)与主钢板(1-1)之间形成空腔柱体(5)，得到复合型钢板；
    (5)将复合型钢板弯曲成带有弧度的、外壁具有凸筋(4)的板片结构；
    (6)在所述板片结构的第二对边设侧壁法兰(9)，得到单元板片(1)；
    (7)将所述单元板片(1)沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
  8. 根据权利要求3所述钢-混凝土复合式隧道衬砌支护结构的制作方法，其特征在于包括如下步骤：
    (1)预备主钢板(1-1)和封堵钢带(11)；
    (2)所述主钢板(1-1)具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔(8-1)得到端部法兰(8)，沿第二对边将主钢板(1-1)向上弯折形成间隔排列的凸筋(4)，该凸筋(4)与主钢板(1-1)形成凹槽(10)，并在凸筋(4)表面开设混凝土浇注孔(6)；
    (3)所述封堵钢带(11)上开设混凝土溢出孔(7)，将封堵钢带(11)贴合于所述凹槽(10)的槽口处，凸筋(4)与封堵钢带(11)之间形成空腔柱体(5)，得到复合型钢板；
    (4)将复合型钢板弯曲成带有弧度的、内壁具有凸筋(4)的板片结构；
    (5)在所述板片结构的第二对边设侧壁法兰(9)，得到单元板片(1)；
    (6)将所述单元板片(1)沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
  9. 根据权利要求4所述钢-混凝土复合式隧道衬砌支护结构的制作方法，其特征在于包括如下步骤：
    (1)预备主钢板(1-1)和封堵钢带(11)；
    (2)所述主钢板(1-1)具有第一对边和第二对边，将其第一对边向上弯折，在弯折部分开设法兰连接孔(8-1)得到端部法兰(8)，沿第二对边将主钢板(1-1)向下弯折形成间隔排列的凸筋(4)，该凸筋(4)与主钢板(1-1)形成凹槽(10)，并在凸筋(4)表面开设混凝土溢出孔(7)；
    (3)所述封堵钢带(11)上开设混凝土浇注孔(6)，将封堵钢带(11)贴合于所述凹槽(10)的槽口处，凸筋(4)与封堵钢带(11)之间形成空腔柱体(5)，得到复合型钢板；
    (4)将复合型钢板弯曲成带有弧度的、外壁具有凸筋(4)的板片结构；
    (5)在所述板片结构的第二对边设侧壁法兰(9)，得到单元板片(1)；
    (6)将所述单元板片(1)沿隧道洞壁周向和轴向拼装形成隧道衬砌支护结构。
  10. 根据权利要求1-4任一所述钢-混凝土复合式隧道衬砌支护结构的施工方法，其特征在于：沿隧道洞壁周向和轴向拼装单元板片；其中，周向拼装时相邻的单元板片通过侧边法兰连接，轴向拼装时相邻的单元板片通过端部法兰连接；按照自下而上的顺序 从混凝土浇注孔内灌注混凝土，直至混凝土充满空腔柱体，并从混凝土溢出孔流出，充满隧道洞壁土层与单元板片的间隙，即可完成施工。
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