HK1227965A1 - Protective element, concrete element, and method for producing a concrete element - Google Patents

Description

Protective element, concrete element and method for producing a concrete element

Technical Field

The invention relates to a protective element for connection to a concrete element of a tunnel lining, having at least one protective section which has a side facing the concrete element, on which side at least one connecting element for establishing a permanent connection of the protective section to the concrete element is provided, wherein the protective section has a bottom section and/or a wall section and at least one region made of at least one plastic, and the protective element has at least one sealing element which is connected in one piece to the protective section, which connection is gas-tight and liquid-tight, and the one-piece connection of the sealing element to the protective section is established by injection molding with the at least one plastic, and in this way a first section of the bottom section and/or the wall section of the protective section is formed.

Background

Such a concrete element or protective element is known from WO2011/085734a 1. Such concrete elements are also referred to in the generic term as "tubbing" and are used, for example, in the construction of mechanical tunnels by means of shield propulsion. For example, tunnel boring machines are used which comprise a drill bit behind which a cylindrical shield is arranged, which shield has a shield shell and a shield tail. The shield has a smaller outer diameter than the drill bit so that there is no direct contact between the tunnel wall and the shield. When the tunnel boring machine is advanced a certain distance forward, in the shield tail, the concrete element is positioned on the shield edge. The concrete elements are pressed against the advancing direction against the adjacent, last applied concrete element and connected to the latter. The concrete elements together form a ring over the entire circumference of the tunnel. The gap between the ring and the tunnel wall is filled with mortar, for example to prevent subsidence.

Furthermore, tunnel constructions of this type are also used for constructing drainage pipelines, in particular larger main pipes. In this case, as well as other possible purposes of use, increased demands are made on the density of the tunnel lining. The inside of the tubbing is sealed with an inner lining so that no waste water and no gas rising from the waste water reaches the concrete via the tunnel wall and can damage (corrode) the concrete.

It is known from WO2005/024183a1 and also from JP2004132002 to prefabricate a tubbing for tunnel lining and already to provide a lining on the inside when manufacturing the tubbing, by means of which a sealing of the tunnel wall against water and gas is achieved in the combined state of the individual tubbing rings. In this case, a protective layer is provided on the concrete element, said protective layer covering the inner surface of the tubbing opposite the convex outer surface. The protective layer is made of glass fiber reinforced plastic or Polyethylene (PE) according to WO2005/024183a1 or of a synthetic resin according to JP2004132002, in particular Polyethylene (PE), polypropylene (PP), polyvinyl chloride, polyester or vinyl ester here, and is fixedly anchored in the concrete by means of mechanical anchoring, so that an inseparable connection of the protective layer to the concrete results. Here, the protective layer is designed such that only the inner side of the tubbing element is covered (JP2004132002) or the side surfaces of the concrete element are also partially enclosed together (WO2005/024183a 1).

According to WO2005/024183a1, a seal is arranged next to the side surface, which seal projects beyond the protective layer. The sealing element is made of an elastic material, so that when the individual tubings for tunnel lining are combined, the joint between the individual adjacent concrete elements is closed by the sealing element.

The concrete element of WO2005/024183A1 is itself made with the help of a formwork. In the formwork, the protective layer is placed on the formwork bottom. In addition, a protective layer element is also placed on the sidewall of the formwork. Furthermore, the formwork has a recess into which the seal engages. Concrete is then introduced into the formwork in connection with the reinforcing bars. After the concrete hardens, the tubbing is used as a tunnel lining.

WO2011/085734a1 shows a development for this. In practice it has been found that: in the arrangement according to WO2005/024183a1, leaks can always occur in the transition between the protective layer and the seal when the seal is embedded in the formwork and/or when the seal is arranged relative to the protective layer when the concrete element is manufactured without sufficient care. As a solution to this, WO2011/085734a1 indicates that the protective element is produced in an injection mold, in which a seal is inserted and is surrounded by the plastic used, as a result of which a liquid-tight and gas-tight connection between the seal and the protective element is established. Polydicyclopentadiene (pDCPD) is disclosed as a particularly advantageous plastic for encasing injection molded seals.

Disclosure of Invention

The object of the present invention is therefore to provide a production method for producing concrete elements and an improved protective layer, wherein the protective element is improved with regard to material input while being sufficiently adherent.

In terms of the protective layer element, the object according to the invention is achieved by: the bottom section and/or the wall section of the protective section have at least one second section which has a planar extension and which is connected to the first section by injection molding.

In the search for improvements to the above-described protective elements, it was surprisingly found that: it is possible to connect at least one prepared section of the protective element to the injection-moldable plastic in such a way that a sufficient tightness of the protective element can be achieved. At the same time, the production costs of the protective element can thus be reduced in a simple manner, since the injection quantity can be reduced and the production and injection mold can thus be simplified.

"injection molding" is understood here to mean all processes which can be incorporated into injection molding, namely the following processes: in the process, one or more thermoplastics/thermosets/elastomers are introduced directly into the mold, for example as polymers or monomers, individually, separately, sequentially or simultaneously, (for example, overmolding or multicomponent molding), or the monomers which only form polymers in the injection mold are processed in the process (for example, reactive overmolding).

A further teaching of the invention provides that the second section is formed substantially from a film, a plate or a strip, which is preferably connected to the connecting element, and/or from a further plastic.

A further teaching of the invention provides that the base section of the protective section is substantially formed by the second section, and/or that the connection between the first section and the second section is a butt connection, or that the first section at least partially surrounds the second section. It is therefore possible that the injection molding is essentially limited to the direct connection of the bottom section to the seal. By the one-piece connection of the seal and the connecting element to the protective section, a liquid-tight and gas-tight connection is established in a particularly simple manner. By injection moulding it can be ensured that the protective element is manufactured with a high quality which remains unchanged, so that the protective effect of the protective element is particularly high and has a high quality which remains unchanged with respect to the manufactured concrete element, irrespective of the manufacturing process of the concrete element. The protective element is formed such that the sealing material is surrounded by injection-molded material on at least three sides with respect to the seal.

A further teaching of the present invention provides that the connecting element is a honeycomb structure, a web, a pin and/or a flat element having an opening. It is also advantageous if the protective section is connected in one piece to the at least one connecting element, wherein the one-piece connection is preferably produced by injection molding of plastic. In particular, the flat elements (for example honeycomb structures or flat sections with continuous openings) allow a particularly good anchoring of the protective element to the concrete element over the entire area of the protective element. The additional provision of pins or the like, which possibly extend further into the concrete of the concrete element, enables an improved increase in the holding force point by point. Since it is provided that the protective element should be able to withstand water pressure at all in the event of damage to the concrete element and thus in the event of possible external water pressure, it is furthermore particularly advantageous if the connecting element is freely provided with regard to its shape and its material selection and a corresponding connection between the connecting element and the protective section can be provided by injection molding, in particular in the case of connecting elements that are not made of plastic. Furthermore, in the case of a connection element of an injection-molded section of the protective section which is also made of the same plastic as the protective element, a particularly high degree of shape versatility for the connection element can be provided due to the injection molding. Furthermore, it is possible to produce the connecting element by extrusion when producing the corresponding section of the protective section.

In this connection, a further teaching of the invention provides that a cover element is additionally provided, so that a hollow body is produced, into which the concrete and, if necessary, the reinforcing ribs are already introduced during the injection molding. The cover element is advantageous when the concrete element also has to be protected on its outside against corrosive water in the rock.

In a further teaching of the invention, the plastic is polydicyclopentadiene (pDCPD) or a resin, the polydicyclopentadiene preferably being in a form resistant to high temperatures, if appropriate with the addition of reinforcing elements, such as glass fibers, to the plastic resin. With such plastics, high production speeds can be achieved on the basis of rapid processing characteristics. While providing particularly high resistance in use.

A further teaching of the invention provides that the plastic of the flat element is a thermoplastic, preferably polyethylene. In particular, low-cost plastics are used here. The components made of this plastic (for example plates, strips or films) can be produced directly at the site in a decentralized manner, so that considerable transport and possibly also storage of the finished products is dispensed with.

In connection with concrete elements for producing tunnel linings, the teaching of the invention provides for the use of the above-described protective elements. By means of such a protective element, a sufficient seam seal can be produced, which provides a corresponding tightness of the protective lining of the tunnel against liquids and gases.

In terms of the production method according to the invention, the solution according to the invention provides that the protective element described above is produced from plastic in an injection molding method, the produced protective element is inserted into a mold, the protective element is connected to the concrete and, after hardening, the protective element is removed from the mold. By prefabricating the protective element in an injection molding method, in which a one-piece connection between the retaining element and the sealing element and the protective section of the protective element is achieved, a simple production method is provided, since the possible sources of defects described above in the production of the concrete element are eliminated, since only a single component has to be introduced into the formwork, and thus the source of defects at the transition of the protective layer to the sealing element is eliminated. At the same time, a connection with high retention between the protective element and the concrete element is provided in a simple manner. It is advantageous here to provide a protective effect that is constant for a sufficient quality of the concrete element even in the case of the concrete element being produced on site at the point of use of the tubbing.

Furthermore, it may be advantageous if the upper side of the concrete element is also provided with a protective element or layer. The protective element or layer can be provided already before or after the concrete is fed into the formwork, for example by painting or the like.

Drawings

The invention is explained in more detail below with the aid of the figures. The attached drawings are as follows:

fig. 1 shows a first perspective view of a concrete element according to the invention;

figure 2 shows a second perspective view of a concrete element according to the invention;

figure 3 shows a side view of a concrete element according to the invention;

figure 4 shows a cross-sectional view of a concrete element according to the invention;

fig. 5 shows a partial enlargement of a sectional view of the corner region according to fig. 4;

fig. 6 to 9 show different embodiments of the protective element according to the invention.

Detailed Description

The concrete element 10 according to the invention (fig. 1 to 3) is a section of a tunnel lining (a tubbing). The section has a convex upper side 11 and an underside 12 arranged opposite the upper side (covered by a protective element 20 in fig. 1 to 3). On the inner side 12 of the concrete element a protective element 20 is arranged. The protective element 20 has a bottom section 21 and wall sections 22, 23. A receiving region 29 is provided on the wall sections 22, 23, in which a seal 30 is arranged. The connection between the seal 30 and the protective element 20 is realized by injection molding.

The protective element 20 has a first section 25 made of an injection-moldable plastic on its wall sections 22, 23. The bottom section 21 has a second section 28 with a planar extension.

In fig. 4, a concrete element 10 is shown in a sectional view, which has a first embodiment of a protective element 20 according to the invention. Fig. 5 shows a partial enlargement of the corner region of fig. 4. Fig. 6 to 9 show further embodiments of the protective element 20.

As shown in fig. 4, the protective element 20 has a base section 21, on the outside of which wall sections 22, 23 are arranged substantially at right angles (but also in any other arrangement). In order to establish a permanent connection between the protective element 20 and the concrete element 10, the inside of the bottom section 21 has a pin element 17. As an alternative and not shown, a web parallel to the outer wall and a web 28 parallel to the outer wall arranged at right angles thereto can also be provided. The webs can be provided, for example, with openings through which concrete 16 can pass and thus produce a particularly well durable connection after hardening. In order to provide a permanent connection of the wall sections 22, 23, projections 27 are provided which engage at an angle of 45 ° to 90 ° on the wall sections 22, 23 and are also provided with openings 26 for establishing the permanent connection.

A seal 30 is arranged in the receiving region 29. The seal 30 is made of an elastomer. The sealing element 30 has a sealing surface 31 which, when the individual concrete elements are combined, comes into contact with the other concrete surface or with the other sealing surface 31 of the sealing element 30. Internally, the seal 30 has a chamber 32. When the individual concrete elements 10 are combined, the elastomer of the seal 30 is deformed and the chamber 32 is compressed. Opposite the sealing surface 31, a retaining projection 33 is provided, which is inserted into the plastic of the side walls 22, 23 of the protective element 20. This side wall and the adjacent side wall of the seal 30 are connected to the plastic of the protective element during injection molding or are surrounded by the plastic in a gas-tight manner.

In the embodiment of the protective element 20 according to fig. 4, a honeycomb structure 24 is provided on the inner side of the base section 21 of the protective element 20. The honeycomb structure may be bonded or otherwise anchored, for example, to the bottom section 21. When the concrete 16 is introduced into the protective element 20, the concrete 16 can be pushed into the honeycomb structure 24 and hardened there. Due to the high surface of the honeycomb 24, there is a large contact area between the honeycomb 24 and the concrete 16, and thus a high holding force after the concrete 16 is hardened. Additional connecting elements are arranged in a supporting manner with respect to the honeycomb structure 24, wherein these additional connecting elements are likewise tabs (not shown) or pin elements 17. The following possibilities exist: the tab and/or the pin 17 is molded from the plastic of the protective element 20, or alternatively or additionally, is made from another material (e.g., metal).

In fig. 4, a reinforcement 15 is provided in addition to the connecting element in the form of a pin 17. The reinforcing ribs are located on the connecting element 17 as shown in fig. 4, or alternatively also on the honeycomb structure 24 or the bottom section 21. Fig. 5 shows a cross-sectional view of a concrete element according to the invention. The reinforcement 15 is surrounded by concrete 16 just as the honeycomb 24 and the webs or pins 17.

As shown in fig. 4, the protective element has a first section 25 which is produced by injection molding and surrounds the seal 30. The first section is made of an injection-moldable material during injection molding. Furthermore, the base section 21 has a second section 28 of the protective element 20. The second section is a planar element 34, for example in the form of a strip, film or plate. The integral component in this embodiment of the second section 28 is the T-shaped pin element 17. These pin elements are arranged on the flat element or these pin elements 17 are made of the same material as the flat element 34. The connection of the flat element 34 is effected by injection molding of the first portion 25.

Fig. 6 to 9 show different exemplary kinds of connection of the second section 28 to the first section 25. The connection can be realized in the form of a butt joint (fig. 6, 7 and 9), or the second section 28 can be surrounded on one side (not shown) or on both sides (fig. 8) by the first section. In fig. 9, the flat elements forming the second portion 28 are provided not only as a constituent part of the bottom portion 21, but also as wall portions 22, 23. As shown in fig. 6, 7 and 9, a butt-joint connection has proven to be sufficient in an unexpected manner, in particular when connecting polyethylene as the flat element 34 and polydicyclopentadiene as the first section 25, which is an injection-moldable plastic. Depending on the requirements of the protective element, it is also possible to provide a plurality of surface-like portions 34, which may be made of different materials, which are then connected to one another by one or more different injection-moldable plastics via a plurality of first portions 25. This applies not only to the bottom section 21, the wall sections 22, 23, but also to the cover section.

The manufacture of the concrete element 10 according to the invention is realized with a formwork having the shape of the subsequent concrete element. Here, the outer shape may be a circular arc section, depending on the shape of the respective tunnel lining element 10. The plan view can be rectangular or trapezoidal, for example. The prepared protective element 20, which is connected in one piece with the seal 30 during its production, is inserted into the formwork. After the insertion of the protective element 20, the reinforcement 15 is inserted into the formwork and the concrete 16 is poured.

Alternatively, the protective element 20 can be designed such that it is a hollow body into which concrete is introduced, whereby the formwork can be dispensed with. The reinforcing ribs 15 are then already introduced into the hollow body during the production thereof or are introduced into the hollow body together with the concrete (fibre reinforcement).

The production of the protective element 20 is carried out in such a way that an injection mold is produced which reflects the shape of the protective element 20. Subsequently, the sealing element 30 is placed in the injection mold on the receiving region 29 provided for this purpose. Furthermore, a flat section 34 is inserted in the form of the bottom section 21 or in the form of a part of the bottom section 21 and/or in the form of a part of the wall sections 22, 23. If the connecting means and/or the reinforcing ribs are to be made of a different material than the protective element itself, additional connecting means and/or reinforcing ribs 15 can additionally be introduced into the injection mold. Next, an injection-moldable plastic is introduced into the injection mold. After the plastic has hardened, the protective element 20 can be removed from the mold and provided for producing the concrete element 10.

On the respective side wall 13 of the concrete elements 10, a cavity (not shown) is provided, into which a bow (not shown) is inserted, in which a pin (not shown) is provided in order to connect the respective concrete elements 10 to one another in a ring. The seals 30 of the concrete elements 10 connected to one another via the bolts are butted against one another and pressed together so that they completely seal the gap or joint between the two concrete elements 10. Thus, when lining a tunnel with concrete elements 10 according to the invention, sealing of the joints between the concrete elements 10 is not necessary.

Furthermore, guide holes (not shown) are provided, into which guide rods (not shown) can be inserted. These guide holes are provided in the respective side wall 14 of the concrete element 10 or as a half element in the side wall 13. The half sections then form the guide bores when the two concrete elements are combined via the bolts. By means of these guide rods, the concrete elements 10 of the subsequent lining ring of the tunnel lining can be positioned precisely in a simple manner, since these elements likewise have guide holes and the guide holes are then introduced into the guide rods.

List of reference numerals

10 concrete element

11 upper side

12 lower side

13 side wall

14 side wall

15 reinforcing rib

16 concrete

17 Pin element

20 protective element

21 bottom section

22 wall section

23 wall section

24 honeycomb structure

25 first section

26 opening

27 projection

28 second section

29 receiving area

30 seal

31 sealing surface

32 chambers

33 holding projection

34 planar element

Claims (9)

1. Protective element for connection to a concrete element (10) of a tunnel lining, having at least one protective section (21, 22, 23) which has a side facing the concrete element (10) on which at least one connecting element (24, 25, 26, 27, 28) for establishing a permanent connection of the protective section (21, 22, 23) to the concrete element (10) is provided, wherein the protective section (21, 22, 23) comprises a bottom section (21) and/or a wall section (22, 23) and at least one region made of at least one plastic, and the protective element has at least one sealing element (30) which is connected in one piece to the protective section (21, 22, 23), which connection is gas-and liquid-tight, and the one-piece connection of the sealing element to the protective section is established by injection molding of the at least one plastic, and in that case a first section of the base section (21) and/or of the wall section (22, 23) of the protective section (21, 22, 23) is formed, characterized in that the base section (21) and/or the wall section (22, 23) of the protective section (21, 22, 23) has at least one second section which has a planar extension and which is connected to the first section by injection molding.

2. Protective element according to claim 1, characterized in that the second section is essentially made of a film, plate or tape, which is preferably connected with a connecting element, and/or the second section is composed of another plastic.

3. Protective element according to claim 1 or 2, characterized in that the bottom section (21) of the protective section (21, 22, 23) essentially consists of the second section and/or the connection between the first section and the second section is a butt connection or the first section at least partially surrounds the second section.

4. Protective element according to one of claims 1 to 3, characterized in that the connecting element is a honeycomb structure (24), a tab (25), a pin and/or a planar element (25, 27, 28) with an opening (26).

5. Protective element according to one of claims 1 to 4, characterized in that the protective section (21, 22, 23) is connected in one piece with the at least one connecting element (24, 25, 26, 27, 28), wherein the one-piece connection is preferably established by injection molding of plastic.

6. The protective element according to one of claims 1 to 5, characterized in that the injection moldable plastic is polydicyclopentadiene (pDCPD) or a resin, said polydicyclopentadiene preferably being resistant to high temperatures, preferably glass fibers being introduced into said resin.

7. Protective element according to one of claims 2 to 6, characterized in that the plastic of the flat element is a thermoplastic, preferably polyethylene.

8. Concrete element for producing a tunnel lining, having a convex outer surface (12) and an opposite inner surface (12), wherein a protective element (20) is connected with the inner surface (12) via at least one connecting element (24, 25, 26, 27, 28), characterized in that the protective element (20) is a protective element according to one of claims 1 to 7.

9. Method for producing a concrete element according to claim 8, wherein the protective element (20) according to one of claims 1 to 7 is produced from plastic in an injection molding method, the produced protective element (20) is inserted into a mold, the protective element (20) is connected to the concrete (16) and, after hardening, is removed from the mold.