EP2239416A2 - Concrete tubing and method for manufacturing the same - Google Patents

Abstract

The tubing has a plastic layer (1) functioning as a permanent formwork while applying a concrete layer (2) in a concrete casting device. The plastic layer is connected with the concrete layer by a granular layer (3) or an open-porous mat. The granular layer is located external to the plastic layer and formed by coarse granules, basalt stones, granite stones, gravel-stones, plastic granulates, metal granulates, shaped parts or steel wool, and the open porous mat comprises plastic, metal or fibers that are arranged in a three-dimensional structure. An independent claim is also included for a method for manufacturing a concrete tubing.

Description

The invention relates to a Betontübbing for producing a tunnel or duct wall in tunnel or sewer construction with a plastic layer on the inside, which serves as a permanent formwork when applying a concrete layer in a concrete pouring device, wherein the plastic layer is connected to the concrete layer, and a method for Production of such.

Large tunnels with a round or vertical oval section are known to be made from prefabricated segments that are joined together. Depending on the mode of use of the tunnel, these segments generally have no or internal plastic coatings. The segments are prefabricated in the pre-driven tunnel tube used by machine. The segment production plant is usually located near large tunnels near the tunnel to be built. The segments replace a formwork that could be backfilled.

Using this technology, for example, fresh water, sewage, cable and traffic tunnels and manholes are produced. The segments are also called segments. Such Betontübbinge be poured into devices with frame-shaped formwork, the base geometry of the geometry of the tunnel is adjusted accordingly, so that the segments together can form the desired tunnel wall. In this case, the required tolerances and side surface guides, which can be formed standing at right angles or at another angle to each other, to take into account and the geometry of the entire ring and the arrangement of the compounds and seals.

Larger tunnels require a variety of shapes to make the segments to be installed. In fresh and sewage tunnels, which must have a water-impermeable acid-resistant corrosion protection inside, z. As a plastic or rubber coating, for example, with 36 molds produced about 30,000 parts per year. This means a high cost of devices and longer life, which are due in particular to the connection of the plastic with the concrete, wherein the plastic layer is provided on the inside and this example is glued as a film. In other tunnels, the coating is done later in the tunnel itself, which is very laborious and costly. The inner layer is also referred to as inliner.

For attaching suspensions, such as cable girders or other devices, the plastic inliners are provided with openings in which dowels can be used. The longitudinal connection between two adjacent segments can also take place via such dowels, which are insertable into recesses in the concrete layer on the face side. Furthermore, it is known to use seals in the form of profiles on the face side in the concrete layers to ensure the collapse of the segments a frontal seal. It is also known to use GRP inliners for sewer pipes, acid or gas tunnels. The plastic coating is for example between 2 mm to 5 mm, the concrete layer has thicknesses between about 10 and about 30 cm, depending on the use.

From the DE 10 2004 010 678 B4 It is known to form a trough-shaped mold body, the bottom and side walls made of plastic, as a permanent formwork, which after filling with concrete on the tubbing remains, wherein the outer side surfaces form a seal to the subsequent next tubbing.

From the EP 1 925 775 A1 is a Betontübbing known for the preparation of a tunnel consisting of a concrete shell to which a lost formwork is glued. This lost formwork can be made of liquid plastic material.

From the DE 2004 010 678 B4 and the DE 198 47 360 C1 It is known to apply to the concrete of a tubbing a plastic layer on the tunnel side and the side walls. For this purpose, thermoplastic sheets are welded onto the precast concrete element, glued or screwed. From the to the patent family of DE 2004 010 678 B4 belonging EP 1 571 292 A1 It is also known to cover this at least partially with a glass or carbon fiber reinforced plastic layer before installing the Betontübbings.

From the DE 10 2006 031 832 A1 a tubbing is known which has a fire protection layer on the inside. The fire protection layer is applied during the production of the body of concrete. Furthermore, it is provided that the base body consists of reinforced concrete or steel fiber concrete. The fire protection layer is connected to the body via connecting or anchoring elements, such as rib projections or rods. The fire protection layer is placed in a shell mold and the concrete body is made by subsequent casting of the concrete in the shell mold on the fire protection layer.

From the DE 44 34 012 C1 an insulating molding in the form of a plate, a cassette or a panel is known which has an insulating core of foam, which is foamed to a cover layer. The top layer is made of a dimensionally stable layer of sand, pebbles, or the like Granular materials formed whose layer thickness is a multiple of the grain diameter of the granular material, during foaming of the insulating core, the foam enters the particle interstices of the granular material and connects the granules firmly together.

It is also known to use a plastic molding plate with molded plastic pins as the inside coating of a tubbing. The prefabricated slab is placed in the mold and backfilled with concrete. The coating or plate is also referred to as inliner. Such an inliner may also have sleeves or dowels embedded in the concrete. Due to the plastic pins, only a selective back anchoring to the concrete is given. The intermediate surfaces are virtually loose. It is known that concrete itself does not have a high adhesive power, which means that it is not impossible that the high water pressure built up in the concrete through the soil presses against the plastic and leads to punctual release solutions. The static pressure of the water can z. B. reach 3 bar to 4 bar. The closed plastic surface is then pressed by the constant pressure load inside and can solve at least selectively.

Based on the prior art, the present invention seeks to provide a Betontübbing with an inside, so the tunnel facing side, plastic layer, which is inextricably linked by a homogeneous surface anchoring with the concrete layer without further additives or manifestations, the preparation of particularly simple way should be feasible inexpensively.

The invention solves the problem by designing the Betontübbings according to the specified in claim 1 technical teaching, which Betontübbing in a Betienengmentgießform can be produced inexpensively according to the manufacturing method specified in claim 11 itself at the processing site of the tubbing.

Advantageous embodiments of Betontübbings according to the invention are specified in the dependent claims 2 to 10, advantageous embodiments of the method in claims 11 to 15.

It has been confirmed that a granule layer introduced into the plastic layer, which forms a firm bond with the plastic, since it partially encloses the granules, forms a particularly large anchoring surface through the projecting surface of the granules with the plastic. Moreover, since the granulate surfaces are at different angles to one another or have oblique edge courses, a surface anchoring of the concrete layer, which is applied to the granulate layer, is given with the plastic layer. The sheet-like anchoring ensures that even at high water pressure in the built tunnel, a detachment of the plastic liner is not given. Instead of the application of granules as bulk material and tissue mats can be applied to which the granules are adhered. These fabric mats have apertures so that the plastic can partially bond to the outer surfaces of the granules while the exposed ends connect to the concrete. Also, instead of granules or granular mats and open-pored mats made of plastic or metal, for example, two-ply expanded metal, or fibers of the specified materials with a three-dimensional structure can be used. It is also possible to use fabrics which have meshes which set up on contact with liquid plastic and thus form a three-dimensional structure. The use of such tailored mats also provides a laminar connection to the concrete.

In principle, the granules used can consist of very different materials. However, these materials should not be swelling due to moisture absorption. Basalt litter, granite stone, gravel litter, plastic or metal granules, as well as plastic and metal injection molded parts have proven to be particularly suitable, which have a certain number of anchoring pins or hollow chamber parts are, for. B. angular or round pipe sections, which are partially interspersed with a plastic adhesive or a plastic compound of the plastic layer and / or enclosed, while the other opening areas are filled by the liquid concrete. Also suitable are steel wool or steel moldings which are enclosed in the same way both by the plastic mass or the plastic adhesive and by the liquid concrete, which forms after hardening with the plastic layer a unitary segment, ie a tubbing, which is buildable. If a plastic adhesive is used, the plastic layer z. B. consist of a 1 mm or 2 mm thick cut film and the adhesive layers are about 3 mm thick.

To avoid osmosis in fiber-reinforced plastic layers is provided in a further embodiment, that the plastic layer is a polyurethane layer and the granules layer is applied in the liquid state, so that the granules are able to sink into the liquid plastic and held by the form and surface bond. The granules are thus partially embedded in the plastic. After curing or curing, the concrete layer is applied. This is advantageously done in the same mold having side wall formworks. The inliner body can also be prefabricated. It is expedient, however, in one pass, both the plastic layer, the granular layer and the concrete layer, taking into account the curing of the Plastic and the setting time of the concrete to bring.

It has been found that by using high density polyurethane which is not foaming, full processing is possible within only four minutes at a layer thickness of 5 mm. By using a two-component polyurethane (polyurethane and hardener) a faster reaction time is achieved, which is less than four minutes. Within these four minutes, the polyurethane layer is sprayed into the mold and the granules are scattered. After four minutes, the high-density polyurethane layer has already hardened to such an extent that the concrete layer can be applied to it. This concrete layer can now z. B. 10 cm, 12 cm or 15 cm or even about 25 cm thick, this depends on the purpose and the mining conditions on site, whether it is, for example, traffic tunnels, sewage or fresh water tunnels or cable tunnel and whether the tunnel runs through rocks or gravel layers.

The segments provided with inliners are mainly used in sewage and fresh water applications but also for gas pipelines. The construction of the segments is usually done immediately behind the tunneling machine by known Segmentsetzmaschinen.

In order to ensure a sealed joining of the segments, it can be provided that the introduced plastic layer has raised edges at the edges, onto which a sealing profile with a U-shaped slot receptacle is placed before casting the mold with concrete. The profile presses with its elastic part against a sealing profile on the next tubbing or against the concrete layer, whereby the desired seal is given.

When introducing the plastic layer into the mold, a sealing profile made of an elastic material can be attached with a corresponding lower, inside edge formation of the mold. This can for example be previously inserted into a groove and has approaches that extend anchoring into the plastic layer. However, such a sealing profile can also be glued subsequently. In a further embodiment, it is provided that the sealing profile is formed from the plastic layer itself. For this purpose, a corresponding deformation profile must be embedded in the edge zone of the mold in the side walls, which is encircled by the plastic or into which the plastic flows. In this way, for example, directly a Nutfederverbindung between corresponding adjacent sides of two segments are made. However, such a profile can also be placed on an upstand in the edge region of the plastic layer.

If the plastic layer is pulled up at least over a defined height dimension at least on two opposite sides, this frame wall can likewise be designed such that a sealing profile made of elastic material can be placed, pressed in or anchored therein. It can also be formed upstands, on which a sealing profile with a U-shaped receptacle can be placed. This upstand should preferably be provided in a U-shaped receptacle, so that an identical design of adjacent segments is possible. But it can also be pressed or formed a groove-shaped receptacle into which the sealing profile made of elastic material can be used. By appropriate shaping and shape adaptation of the groove and the sealing profile, a latching connection can be achieved at least on one side of adjacent segments, while the other part of the sealing profile when joining the two segments only engages in a groove of the adjacent tubbing. In the groove of this tubbing but also a profiling can be provided for connection. If such profiles are not provided, then the sealing profile is glued into a groove only so that it can engage sealingly in the groove in the adjacent frame wall of the adjacent tubbing when joining the segments. In the production of the frame wall, such a sealing profile can be provided with anchoring elements, but also fastened at the same time.

The segments may also have openings for receiving a sleeve or a dowel. In such breakthroughs, other fasteners can be introduced in order to fasten, for example, carrier for cables can. These fasteners are thus fixed to the surface.

Also, carbon and / or glass fibers can be introduced into the plastic layer in a known manner in order to enable a higher mechanical load. When used in sewage and fresh water tunnels, however, it has been shown that detachment of the plastic from the fiber can not be ruled out by osmosis occurring here. In sewage and fresh water tunnels, therefore, the use of high-density polyurethane of A and B components as a plastic coating mass has proven to be the optimum solution in tests.

Of course, reinforcing mats made of plastic or metal fabric and / or mesh can be inserted to increase the load capacity in the concrete layers. This can cause the concrete layers to be reduced in thickness, resulting in material and weight savings. The introduction of the liquid plastic in the mold also allows that At the edge of a sealing profile can be formed. An already created sealing profile made of elastic material can also be inserted as an edge profile in the plastic layer. If a molding of a sealing profile, so it is advisable to form at two angles to each other arranged sides of the tubing sealing lips as springs, the corresponding attachment sides of the next tubbing have contour-matched sealing profiles. For example, may be provided on the two sides of a bead-shaped sealing lip and on the other two sides of a continuous groove into which the sealing lip on the next tubbing is inserted. Thus, when joining the segments, a tongue-and-groove connection is created, which is self-sealing. The Anformung lends itself to because the plastic layer is entered in liquid form into the mold and thereby also Randausformungen be possible by trailing. However, the formwork walls must then be movably mounted so that they can be moved apart for the shaping of the tubbing.

The shape itself can be made in several parts, in order to produce several segments simultaneously. But it can also be made in one piece. The polyurethane layer can be poured in or else sprayed in, for which purpose a spray head distributes the liquid plastic over the surface. The liquid plastic is kept at temperature throughout the overreach until it emerges from the spray head. After application or during the application of the plastic layer, the granules can already be sprinkled in the region which has the desired plastic layer thickness. This can also be done by a distribution head, which scatters the granules at a lower speed or with a time delay on the plastic layer. But it is also possible by separate pipes with exit slot the granules Spread evenly across the width. The granules fall with the lower sections in the still liquid plastic material. This encloses cavities, undercuts, in short, all the surface parts of the granules that sink into the plastic. The granules are firmly bound. Will now after a curing time of z. B. four minutes applied the plastic layer, the liquid concrete surrounds the protruding from the plastic mass granule surface sections and adheres to the surfaces. Again, granule parts are engaged behind or filled cavities, so that a surface anchoring of the entire plastic inliner is given. In the liquid plastic mass along the frame wall, a sealing profile made of an elastic plastic or rubber-like material can be inserted, which allows a side seal when joining the segments.

The invention will be explained in the following with reference to the embodiments illustrated in the drawings.

FIG 1

in einer perspektivischen Darstellung einen Tübbing, der als Einzelbestandteil eines runden Tunnels gefertigt ist,

FIG 2

einen Teilquerschnitt durch den Tübbing in Figur 1, aus dem ersichtlich ist, dass in die Kunststoffschicht ein Granulat, hier ein Basaltgranulat, eingebunden ist,

FIG 3

eine Ausführung, bei der die Dichtungsprofile an den Stirnseiten angeformt sind,

Fig. 4

ein Beispiel eines Tübbings mit einer Rahmenwand aus Kunststoff nach der Erfindung mit eingeformter Nut zur Aufnahme eines Dichtungsprofils und

Fig. 5

ein Beispiel der Verankerung eines Dichtungsprofils an einer Rahmenwand.

In the drawings show:

FIG. 1

in a perspective view a tubbing, which is made as a single component of a round tunnel,

FIG. 2

a partial cross section through the tubbing in FIG. 1 from which it can be seen that a granulate, in this case a basalt granulate, is incorporated in the plastic layer,

FIG. 3

an embodiment in which the sealing profiles are integrally formed on the end faces,

Fig. 4

an example of a tubbing with a plastic frame wall according to the invention with molded groove for receiving a sealing profile and

Fig. 5

an example of the anchoring of a sealing profile to a frame wall.

The embodiment in FIG. 1 shows a plastic view 1, which is introduced into a box-shaped form by means of a spray head. It is a consisting of components A and B polyurethane layer. The mold also has a pin, so that the opening 4 is already exposed during spraying. In this breakthrough 4, for example, a dowel can be used to attach it to fasteners can. On the plastic layer 1, a granular layer 3 is applied in the liquid state of the plastic, the FIG. 2 is apparent. It is a basalt layer, so that parts of the basalt are embedded in the plastic and fixed therein, while the other sections protrude. On the cured plastic concrete layer 2 is applied in the same form. The liquid concrete combines with the basalt stones of the basalt layer, so that there is a surface-shaped anchoring, which extends in the third dimension, over the adhesion surfaces on the basalt stones. After the setting time of the concrete, the finished tubbing can be removed from the mold.

FIG. 3 shows a sealing profile, which consists of a groove 5 and a next tubbing from a bead-shaped spring 6. These are automatically formed in the mold. For this purpose, the side shells of the form are movable and have the corresponding negative embodiments of each two abutting Pages on, so that in the composite tubules on the insides are completely insulated.

Fig. 4 shows in the form of a section of a tubbing an embodiment in which in a frame wall 7 on the base layer, the plastic layer is shown pulled up, into which by corresponding rib arrangement on the inside of the mold, a groove 8 is formed. Also, the inside of the frame wall 7 has the granules of the invention or a three-dimensional mat to produce the desired bond to the subsequently poured concrete layer 2. This groove 8 may be provided circumferentially in the frame walls 7, so that all segments are structurally executable. Subsequently, the sealing profile 9, which may for example consist of different plastics or rubber compounds, adhered to the bottom side. An adhesive bond may also be provided in a connection with the adjacent tubbing in the corresponding groove. But it is sufficient a frictional connection to ensure the desired seal.

In Fig. 5 is a section of a tubing shown, which shows that when the sealing profile 9 is provided with anchoring elements 10, the sealing profile 9 in the manufacture of the plastic liner, so the plastic layer can be poured with the anchoring elements. Subsequent sticking or vulcanization is not required.

LIST OF REFERENCE NUMBERS

1

Plastic layer

2

concrete layer

3

granule layer

4

breakthrough

5

groove

6

sealing lip

7

frame wall

8th

groove

9

weatherstrip

10

anchoring element

Claims (15)

Betontübbing for producing a tunnel or duct wall in tunnel or sewer construction with a plastic layer on the inside, which serves as permanent formwork when applying a concrete layer in a concrete casting, wherein the plastic layer is connected to the concrete layer, characterized in that the plastic layer (1 ) is connected to the concrete layer (2) by a granular layer (3) of coarse-grained granules introduced on the outside of the plastic layer or by an open-pored mat of plastic or metal or fibers of these materials having a three-dimensional structure. Betontübbing according to claim 1, characterized in that the granular layer (3) consists of basalt litter, granite stone, gravel litter, plastic or metal granules or moldings or steel wool or a mixture of at least two of the said components. Betontübbing according to claim 1 or 2, characterized in that the plastic layer (1) is a polyurethane layer and in the liquid state, the granule layer (3) is applied and the granules are partially embedded in the plastic and after curing or hardening the concrete layer (2). is applied. Betontübbing according to claim 1, characterized in that in the plastic layer (1) at least one opening (4) for receiving a sleeve or a dowel or for mounting or attaching other fastening means is provided. Betontübbing according to claim 1, characterized in that in the plastic carbon or glass fibers are introduced. Betontübbing according to claim 1, characterized in that in the concrete layer (2) reinforcing mats made of plastic or metal fabric and / or braid or other reinforcements are inserted. Betontübbing according to claim 1, characterized in that on the plastic layer edge running a sealing profile (9) made of elastic material, pressed, anchored or molded or on a Aufkantung the plastic layer, a sealing profile (9) is placed with a U-shaped receptacle. Betontübbing according to claim 1, characterized in that the plastic layer is pulled up on at least two opposite sides at least over a defined height dimension and a frame wall (7) and that on the frame wall (7) a sealing profile (9) made of elastic material, pressed , anchored or molded or on a Aufkantung the plastic layer, a sealing profile (9) is placed with a U-shaped receptacle or groove-shaped receptacles (8) congruent in the sides of the frame walls (2) of adjacent Betontübbinge for receiving a sealing profile (9) made of elastic Material are provided. Betontübbing according to claim 1, 7 or 8, characterized in that the plastic layer (1) at two at an angle, preferably at a right angle, abutting end faces a continuous groove (5) and on the two other sides a bead-shaped sealing lip (6 ), which correspond to the groove (5) of the next tubbing is attached, such that two segments are sealingly against each other during installation by tongue and groove connection. Betontübbing according to claim 1, 7 or 8, characterized in that the groove-shaped receptacles (8) in the frame walls (7) of Betontübbings are inserted circumferentially and that the sealing profile (9) inserted, glued or anchored embedded therein. A method for producing a Betontübbings according to claim 1, characterized in that a polyurethane layer is introduced into a segmental shape, that on the surface of a granular layer via a feed arrangement having an outlet slot over the width of the tubbing, or by a distribution head, via a feed line the granules is distributed by head movement over the surface, scattered or that an open-pored mat made of plastic, metal or fibers of these materials is applied with a three-dimensional structure and that the plastic layer is removed after curing and inserted into a concrete casting mold or in the form of Filling with concrete remains and the mold is filled with concrete. A method according to claim 11, characterized in that the segmental shape on two sides of the frame in the interior projecting ribs to form grooves in the plastic mass and on the two opposite sides in the frame wall of the mold has a groove for forming a spring on the plastic mass and that the frame is opened relative to the base for lifting a finished tubbing. A method according to claim 11 or 12, characterized in that in the liquid plastic mass along the frame wall (7) has a sealing profile (9) of a elastic plastic or rubber-like material or in a molded groove is inserted. A method according to claim 13, characterized in that in the frame wall of the mold for receiving the sealing profile recesses are provided. A method according to claim 11, characterized in that the polyurethane layer is introduced with a spray head into the mold and that time-delayed, during the curing time, by a tracking distributor head, the granules are scattered.

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