ES2812554T3 - Protection element, concrete element and procedure for the manufacture of a concrete element - Google Patents

Abstract

Protection element for connection to a concrete element (10) of a tunnel shoring, which has at least one protection section (21, 22, 23), which has one side facing the concrete element (10), in which at least one connecting element (17, 24) is provided for establishing a lasting connection of the protection section (21, 22, 23) with the concrete element (10), where the protection section ( 21, 22, 23) has a bottom section (21) and a wall section (22, 23) and at least one area made from at least one first plastic, where the protection element has at least one sealing gasket (30), which is connected in one piece with the protection section (21, 22, 23), where the connection is gas-tight and liquid-tight, and the one-piece connection of the gasket (30) with the protection section is established by injection molding with the at least one first plastic, and where a first s The section of the wall section (22, 23) from the protection section (21, 22, 23) is manufactured by injection molding with the at least one first plastic, characterized in that the bottom section (21) of the protection section protection (21, 22, 23) has at least a second section, because the second section is formed from another plastic, because the second section has a flat extension, and because the second section is connected to the first section by molding. injection with the at least one first plastic.

Description

DESCRIPTION

Protection element, concrete element and method for manufacturing a concrete element The invention relates to a protection element for connection to a concrete element of a tunnel shoring, which has at least one protection section, which has a side facing the concrete element, on which at least one connecting element is provided for the establishment of a durable connection of the protection section with the concrete element, where the protection section has a bottom section and a wall section and at least one area made from at least a first plastic, where the protection element has at least one sealing gasket, which is connected in one piece with the protection section, where the connection is gas-tight and liquid-tight, and the one-piece connection of the gasket with the protection section is established by injection molding with the at least one p first plastic, and where a first section of the wall section of the protection section is manufactured by injection molding with the at least one first plastic.

Concrete elements or protective element of this type are known from WO 2011/085734 A1. Such concrete elements are also referred to in technical parlance as "tube segment" and are used eg. ex. in machine tunnel construction by means of a shield advance. In this connection, for example, tunnel boring machines comprising a drilling head are used, behind which a cylindrical shield with a shield casing and a shield tail is arranged. The shield is smaller outside diameter than the drill head, so there is no direct contact between the tunnel wall and the shield. When the TBM has been driven forward a certain section, the concrete elements are positioned at the edge of the shield in the shield tail. They are pressed against and connected to the adjacent concrete elements, placed last in the opposite direction to the direction of advance. Several concrete elements together form a ring over the entire circumference of the tunnel. The gap between ring and tunnel wall is filled with mortar, eg. ex. to prevent subsidence.

This type of tunnel construction is also used inter alia for the construction of sewage pipes, in particular of larger collecting pipes. In this regard, as in other possible purposes of use, high requirements are also placed on the tightness of the tunnel lining. The inner side of the tube segments is sealed with a lining, so that no waste water and gases rising from the waste water through the tunnel walls can get into the concrete and damage it (corrosion).

From document WO2005 / 024183A1 and possibly from document JP2004132002 it is known that the tube segments used for tunnel shoring are produced previously, and that already during the production of the tube segments a coating is arranged on the inner side, to through which, in the assembled state of the tube segment rings, the tunnel wall is sealed against water and gases. In this connection, a protective layer is provided on the concrete element, which covers an inner surface of the tube segment opposite a convex outer surface. This protective layer is made according to document WO 2005/024183 A1 of plastic with glass fibers or polyethylene (PE) or according to document JP2004132002 of a synthetic resin and in this case in particular of polyethylene (PE), polypropylene (PP) , PVC, polyester or vinyl ester and is fixedly anchored in the concrete by means of mechanical anchoring, so that an inseparable connection of the protective layer with the concrete is created. In this regard, the protective layer is designed in such a way that only the inner side of the tube segment element (JP2004132002) is covered or also a lateral surface of the concrete element is also partially enclosed (WO2005 / 024183A1).

According to WO2005 / 024183A1, a sealing gasket is provided next to the side surface, which exceeds the protective layer. The sealing joint is made of an elastic material, so that when the individual tube segments are assembled for tunnel shoring, the joints between adjacent concrete elements are closed by the sealing joint.

The concrete element of document WO2005 / 024183A1 itself is manufactured by means of a formwork. In the formwork, a protective layer is placed on the formwork base. In addition, the protective layer elements are also placed on the side walls of the formwork. Furthermore, the formwork has a recess into which the sealing gasket is inserted. The concrete is then driven into the formwork in connection with the reinforcement. After the concrete has hardened, the pipe segment is inserted as tunnel shoring. Document WO 2011/085734 A1 shows an improvement of this. In practice, it has been found that in the arrangement according to document WO2005 / 024183A1, at the transition between the protective layer and the sealing gasket, leaks can always appear later, when not enough care has been used in the manufacture of the concrete element. during the insertion of the seal in the formwork and / or during the arrangement of the seal in reference to the protective layer. As a solution to this, document WO 2011/085734 A1 shows for this that the protection element is manufactured in an injection mold, in which the sealing gasket is inserted and surrounded with the used plastic, thus establishing a liquid-tight or gas-tight connection between the sealing gasket and protection element. Polydicyclopentadiene (pDCPD) is disclosed as a particularly advantageous plastic for over-injection of the seal.

Therefore, the object of the invention is to provide a manufacturing method for a concrete element and an improved protection layer, in which the protection element is improved in the case of sufficient adhesion with a view to the use of materials.

With regard to the protective layer element, the object according to the invention is achieved in that the bottom section of the protective section has at least a second section, because the second section is made of another plastic, because the second section has an extension flat and because the second section is connected to the first section by injection molding.

Surprisingly, when seeking the improvement of the protection element represented above, it has turned out that it is possible to connect at least a prepared section of the protection element with the plastic suitable for injection molding, so that a sufficient sealing of the element can be achieved. of protection. Simultaneously, in this way, the manufacturing costs of the protection element can be reduced in a simple way, since it is possible on the one hand to reduce the amount of injection molding and thus simplify the manufacturing and the injection mold.

Injection molding is understood here to be all processes that can be subsumed under injection molding, that is to say processes in which one or more thermoplastic / duroplastic / elastomeric materials are introduced directly, for example as polymers or also monomers into a mold alone, individually, one after the other or simultaneously (for example overmolding / overmolding or multicomponent injection molding) or are processed in the case of their monomers, which first become polymers in the injection mold (for example, reaction overmoldig ).

Another teaching of the invention provides that the second section consists essentially of a film, a plate or a strip, which is preferably connected with connecting elements.

Another teaching of the invention provides that the bottom section of the protection section is essentially formed by the second section and / or that the connection between the first and second section is a butt connection or that the first section surrounds at least partially by sections the second section. In this way it is possible to limit the injection molding essentially to the direct connection of the bottom section with the seal. The one-piece connection of the seal and the connection elements to the protective section provides a particularly simple way to establish a liquid-tight and gas-tight connection. Thanks to injection molding it can be ensured that the protection elements are manufactured with consistently high quality, so that, in reference to the finished concrete element, the protection effect of the protection element is especially high and of consistently high quality, regardless of the concrete element manufacturing process. In this connection, the protection element is designed in such a way that, relative to the seal, there is provided an enclosure provided on three sides of the sealing material with the injection molding material.

Another teaching of the invention provides that the protection element is a honeycomb structure, a rib, a pin and / or an apertured surface element. Furthermore, it is advantageous that the protection section is connected in one piece with the at least one connecting element, where preferably the one-piece connection is manufactured by injection molding the at least one first plastic. In particular, surface elements, such as honeycomb structures or surface sections with through openings, allow a particularly good anchoring of the protection element with the concrete element over the entire surface of the protection element. The additional provision of pins or the like, which eventually reach the concrete of the concrete element, a high increase in the point holding force can be achieved. Since it is provided that the protection element, in the event of a deterioration of the concrete element and consequently possibly water pressure from outside, the protection element must be fully capable of maintaining the water pressure, moreover, it is particularly advantageous that the connecting elements are freely available in their shape and in their choice of materials, and that by injection molding, in particular in the case of locating elements, which are not made of plastic, a corresponding connection can be provided between connecting element and protection section. Furthermore, for the case that the connection elements of the injection molded section of the protection section are also made of the same plastic as the protection element, conditioned by the injection molding a particularly high variety of shapes can be provided for connecting elements.

Another teaching of the invention provides in this context that, in addition, a roof element is also provided, of Thus, a hollow body is generated, into which the concrete and possibly the reinforcement are then introduced already during injection molding. This is particularly advantageous when the concrete element must also be protected on its outer sides against aggressive waters in the mountains.

Another teaching of the invention provides that the plastic is a polydicyclopentadiene (pDCPD), preferably in a form resistant to high temperatures, or a resin, where reinforcing elements, such as glass fibers, are eventually added to the plastic resin. . With this plastic a high product speed can be achieved due to the fast processing properties. At the same time, a particularly high resistance during use has resulted.

Another teaching of the invention provides that the plastic of the surface element is a thermoplastic material, for example PE. In this case, they are especially inexpensive plastics. The components of these, such as plates, bands or films, can be manufactured directly on site in a decentralized way, so that the considerable cost of transport and possibly also the cost of storage of the finished products are eliminated.

With a view to the concrete element for the manufacture of a tunnel shoring, the teaching of the invention foresees that a protection element described above is used. By means of such a protective element, it is possible to produce a sufficient joint seal, which provides a corresponding tightness of the tunnel protective lining against liquids and gases.

With a view to the manufacturing method according to the invention, the solution of the invention provides that a protection element described above is manufactured from a plastic in the injection molding process, the finished protection element is inserted into a mold, which the protection element is connected with concrete and removed from the mold after hardening. Thanks to the prefabrication of the protection element in the injection molding process, in which a one-piece connection is made between the clamping elements and sealing gasket with the protection section of the protection element, a process of Simple fabrication, since possible sources of error described above in the manufacture of the concrete element are eliminated, since only a single component has to be inserted into the formwork, so that the source of error of the layer transition is eliminated protection to the sealing gasket. Simultaneously, in a simple way a connection with high clamping force is provided between the protection element and the concrete element. In this connection, it is advantageous that a sufficient, qualitatively constant protection effect is also provided for the concrete elements at the site of use of the tube segments during an on-site production of the concrete elements.

Furthermore, it may be advantageous if the upper side of the concrete elements is provided with a protection element or a protection layer. In this connection, this protective element or the protective layer can be provided already before the concrete is fed into the formwork or also only afterwards, for example by means of a layer of paint or the like.

In the following, the invention is explained in more detail by means of the drawings.

In this respect they show:

Fig. 1 a first spatial view of a concrete element according to the invention,

Fig. 2 a second spatial representation of the concrete element according to the invention,

Fig. 3 a side view of the concrete element according to the invention,

Fig. 4 a sectional view through the concrete element according to the invention,

FIG. 5 an enlarged fragment of a sectional view of a corner area according to FIG. 4, and

Fig. 6 to 9 different embodiments of the protection element according to the invention

A concrete element 10 according to the invention (fig. 1 to fig. 3) is a segment section ( Tübbing) of a tunnel shoring. The segment section has a convex upper side 11 and a lower side 12 arranged opposite it (in fig. 1 to 3 hidden by a protection element 20). On the inner side 12 of the concrete element the protection element 20 is arranged. The protection element 20 has a bottom section 21 and wall sections 22, 23. In these wall sections 22, 23 a receiving area is provided 29, in which a gasket 30 is arranged. The connection between gasket 30 and sealing element protection 20 is made by injection molding.

The protection element 20 has in its wall sections 22, 23 a first section 25 made of a plastic suitable for injection molding. The bottom section 21 has a second section 28 with a flat extension. The concrete element 10 is represented in section in FIG. 4 with a first embodiment of the protection element 20 according to the invention. Fig. 5 shows an enlarged fragment of the corner area of fig. 4. Other embodiments of the protection element 20 are represented in figs. 6 to 9.

The protection element 20 has, as represented in FIG. 4, a bottom section 21, on the outer sides of which wall sections 22, 23 are arranged essentially at right angles, however also in any other arrangement. In order to establish a durable connection between the protection element 20 and the concrete element 10, the inner side of the bottom section 21 has pin elements 17. Alternatively, and not shown, ribs can also be arranged parallel to an outer wall. and ribs for the outer wall arranged at right angles thereto. The ribs can be provided, for example, with openings through which the concrete 16 can pass and thus generates a particularly durable connection after hardening. To facilitate a durable connection of the wall sections 22, 23, a projection 27 is provided which strikes at an angle of 45 - 90 ° on the wall section 22, 23 and is also provided with openings 26 for the establishment of a lasting connection.

The seal 30 is arranged in a receiving area 29. The seal 30 is made of an elastic plastic. The sealing gasket 30 has a sealing surface 31, which in the case of assembly of the individual concrete elements impinges on another concrete surface or another sealing surface 31 of a sealing gasket 30. Inside the sealing gasket 30 has chambers 32. When the concrete elements 10 are assembled, the elastic plastic of the sealing gasket 30 is deformed and the chambers 32 are compressed. the plastic of the side wall 22, 23 of the protection element 20. This and the nearby side walls of the gasket 30 are connected during injection molding with the plastic of the protection element or are surrounded by it in a watertight manner. gases.

In the embodiment of the protection element 20 according to FIG. 4, a honeycomb structure 24 is arranged on the inner side of the bottom section 21 of the protection element 20. This can be glued or anchored in another way, for example with the bottom section 21. During the introduction of the concrete 16 in the protection element 20, the concrete 16 can penetrate into the honeycomb structure 24 and harden there. Due to the high surface area of the honeycomb structure 24 there is a large contact surface between the honeycomb structure 24 and the concrete 16, so that after hardening of the concrete 16 there are high clamping forces. In favor of the honeycomb structure 24, other connection elements are provided, which are likewise ribs (not shown) or pin elements 17. There is the possibility of forming ribs and / or pins 17 from a plastic of the protection element 20 or alternatively or in addition, provide these made of another material, for example metal.

In fig. 4 an armature 15 is provided in addition to the connecting elements in the form of pins 17. The armature rests, as represented in fig. 4, on the connecting elements 17 or it may alternatively rest on the honeycomb structure 24 or the bottom section 21. FIG. 5 shows a section through a concrete element according to the invention. In this regard, the armature 15 is surrounded, such as the honeycomb structure 24 and the ribs or pins 17, by the concrete 16.

As represented in FIG. 4, the protection element has a first section 25, which is made by injection molding and comprises the seal 30. It is made of a material suitable for injection molding during injection molding. Furthermore, the bottom section 21 presents a second section 28 of the protection element 20. This is a flat element 34, for example, in the form of a band, film or plate. The T-shaped pin elements 17 are an integral part in this embodiment of the second section 28. These are arranged on the flat element or the pin elements 17 are made of the same material as the flat element 34. The connection of the flat element 34 is made by injection molding the first section 25. Figs. 6 to fig. 9 show different types of connection of the second section 28 with the first section 25 by way of example. This can be butt (fig. 6, 7 and 9) or the second section 28 is wrapped on one side (not shown) or on both sides (fig. 8) by the first section. In fig. 9 the flat element forming the second section 28 is provided not only as a component of the bottom section 21, but also as a wall section 22, 23. Surprisingly, the butt connection, as represented in FIG. 6, 7 and 9, it has proved to be sufficient in particular in the connection of PE as flat element 34 and pDCPD as plastic of the first section 25 suitable for injection molding. Depending on the requirement of the protection element, it is also possible to provide several flat sections 34 possibly made of different materials, which are then connected to each other via several first sections 25 through one or several different plastics suitable for injection molding. This is valid both for the bottom section 21, wall section 22, 23 as well as ceiling sections.

The manufacture of a concrete element 10 according to the invention is carried out in such a way that a formwork is provided, which has the shape of the subsequent concrete element. In this regard, depending on the shape of the individual tunnel shoring elements 10, the outer shape may be a circular segment section. The plan view can be made, for example, rectangular or trapezoidal. In this formwork a prepared protection element 20 is inserted, which has been connected in one piece with the sealing gasket 30 during its manufacture. After the insertion of the protection element 20, the reinforcement 15 is inserted into the formwork and the concrete 16 is poured.

Alternatively, the protection element 20 can be made so that it is a hollow body into which the concrete is introduced, whereby the formwork can be dispensed with. The reinforcement 15 is then introduced already during the manufacture of the hollow body or together with the concrete (fiber reinforcement) in it.

The production of the protection element 20 is carried out in such a way that an injection mold is produced, which reproduces the shape of the protection element 20. Next, in the injection mold, the sealing gasket 30 is provided in the intended receiving area 29 for it. Furthermore, the flat sections 34 are inserted into the mold as a bottom section 21 or as part of the bottom section 21 and / or as part of the wall sections 22, 23. Additionally, other connecting means and / or armor 15 in the injection mold, as long as they must be made of another material than the protection element itself. The plastic suitable for injection molding is then fed into the injection mold. After the plastic has hardened, the protection element 20 can be removed from the mold and provided for the manufacture of the concrete element 10.

In the side walls 13 of the concrete element 10 there are arranged cavities (not shown), in which stirrups (not shown) are inserted, in which bolts (not shown) are arranged, in order to connect the concrete elements together. 10 individuals forming a ring. The watertight joints 30 of the concrete elements 10 connected to each other through the bolts collide with each other and are pressed in such a way that they completely seal the gap or the joint between the two concrete elements 10. In the lining of a tunnel with the concrete elements 10 according to the invention therefore does not need a sealing of the joints between the concrete elements 10.

Furthermore, guide holes (not shown) are provided into which guide bars (not shown) can be inserted. The guide holes are provided in the side walls 14 of the concrete elements 10 or as semi-elements in the side walls 13. During the assembly of two concrete elements through the bolts, these semi-segments then form the guide hole. With the aid of the guide bars, the concrete elements 10 of the subsequent shoring ring of the tunnel shoring can be precisely positioned in a simple way, since these elements also have the guide holes and the guide holes are inserted then on the guide bars.

List of references:

10 Concrete element

11 Top side

12 Bottom side

13 Side wall

14 Side wall

15 Armor

16 Concrete

17 Pin element

20 Protection element

21 Bottom section

22 Wall section

23 Wall section

24 Honeycomb structure

25 First section

26 Aperture

27 Outgoing

28 Second section

29 Reception area

30 Sealing gasket

Shutter surface Camera

Clamping boss Flat element

Claims (12)

1. Protection element for connection to a concrete element (10) of a tunnel shoring, which has at least one protection section (21, 22, 23), which has one side facing the concrete element (10 ), in which at least one connecting element (17, 24) is provided for the establishment of a lasting connection of the protection section (21, 22, 23) with the concrete element (10), where the connecting section protection (21, 22, 23) has a bottom section (21) and a wall section (22, 23) and at least one area from at least one first plastic, where the protection element has at least one gasket seal (30), which is connected in one piece with the protection section (21,22, 23), where the connection is gas-tight and liquid-tight, and the one-piece connection of the seal (30 ) with the protection section being established by injection molding with the at least one first plastic, and where a first section of the wall section (22, 23) of the protection section (21, 22, 23) is manufactured by injection molding with the at least one first plastic, characterized in that the bottom section (21) of the section of protection (21, 22, 23) has at least a second section, because the second section is formed from another plastic, because the second section has a flat extension, and because the second section is connected to the first section by molding. injection with the at least one first plastic. Protection element according to claim 1, characterized in that the second section consists essentially of a film, a plate or a strip. Protection element according to claim 2, characterized in that the second section is connected with connecting elements. Protection element according to any of claims 1 to 3, characterized in that the bottom section (21) of the protection section (21,22, 23) is essentially formed by the second section and / or in that the connection between the first and second section is a butt connection or because the first section at least partially surrounds the second section in sections. Protection element according to any one of claims 1 to 4, characterized in that the connecting element is a honeycomb structure (24), a rib, a pin and / or an apertured surface element (26). Protection element according to any one of claims 1 to 5, characterized in that the protection section (21, 22, 23) is connected in one piece with the at least one connection element (17, 24). Protection element according to claim 6, characterized in that the one-piece connection is established by injection molding of the at least one first plastic. Protection element according to any of claims 1 to 7, characterized in that the first plastic suitable for injection molding is a polydicyclopentadiene (pDCPD) or a high temperature resistant polydicyclopentadiene, or a resin, or a resin in which they are incorporated fiberglass. Protection element according to any one of claims 1 to 8, characterized in that the plastic of the second section is a thermoplastic material. 10. Protection element according to claim 9, characterized in that the thermoplastic material is a polyethylene (PE). 11. Concrete element for the elaboration of a tunnel shoring with a convex outer surface (11) and an opposite inner surface (12), where a protection element (20) is connected to the inner surface (12) through at least one connecting element (17, 24), characterized in that the protection element (20) is a protection element according to any of claims 1 to 10. 12. Process for the manufacture of a concrete element according to claim 11, wherein a protection element (20) according to any of claims 1 to 10 is manufactured from plastic in the injection molding process, the protection element Finished (20) is inserted into a mold, the protection element (20) is connected with concrete (16) and is removed from the mold after hardening.