METHOD OF MANUFACTURING A TUNNEL OR SHAFT LINING OR PIPELINE

Abstract: A method of manufacturing a tunnel (10) or shaft lining or pipeline of segments (12), wherein each segment (12) comprises a concrete body (11) having an extrados (13) surface, an intrados (14) surface and first and second ends (15, 16) and first and second sides (17, 18), the ends (15, 16) and sides (17, 18) providing edge portions, the segments (12) being adapted to be connected to further similar segments (12) with edge portions adjacent edge portions of adjacent segments (12), the method being characterised in that the method includes enveloping the ends (15, 16) or sides (17, 18) of at least a pair of segments (12) in a reinforcing material as the concrete is cast, and once the concrete has cured, connecting the segments (12) together with one of each of their enveloped ends (15, 16) or sides (17, 18) adjacent, and sealing between the enveloped ends or sides.

Description: Title: Method of Manufacturing a Tunnel or Shaft Lining or Pipeline Description of Invention This invention relates to a method of manufacturing a tunnel or shaft lining or pipeline of segments each of which is adapted to be connected to further segments. For brevity the remainder of this specification will refer in general to tunnel linings, but this should in all situations be taken also to include shaft linings and the like. Where appropriate pipelines will also be discussed. It is well known to manufacture of tunnel linings using curved segments connected end to end and side to side . In addition the manufacture of pipe linings from segments connected end to end is also well known. Such segments typically are formed from concrete with internal reinforcement of steel bars. However, there are disadvantages with such internally reinforced segments both in terms of the gradual degradation of the steel reinforcement and in terms of sealing the segments in fluid tight fashion to one another. This latter disadvantage is largely as a result of the nature of the concrete surfaces against which such seals press, which commonly have many irregularities. In Japanese patent specification JPO 1-154996 there is disclosed a method of making a curved lining segment in which a concrete core is lined externally widi fibre reinforced cement mouldings. Each of a pair of mouldings is of a generally tray shaped configuration having a base and outstanding sides. The mouldings are arranged with the outstanding sides of the two frays facing one another. Concrete is then introduced into a substantially closed cavity thus produced, to form the segment. Such a construction may simplify the manufacturing process, but it is necessary for the core to be provided with reinforcement as the cement mouldings will not provide substantial structural strength to the core. First, this is because of the nature of cement mouldings. Cement, like concrete is not sfrong in tension, which is why it is essential to provide concrete with some reinforcement which is sfrong in tension. Second, if such internal reinforcement was not included in the construction described in the earlier Japanese patent specification, it would be necessaiy for the edge portions, or at least a pair of the edge portions of the concrete core, to be reinforced to give the segment tensile strength. In the Japanese construction though, the outstanding sides of the two frays meet along the edge poitions of the concrete body, so that regardless of the material from which the cement mouldings may alternatively be made, the mouldings cannot give any substantial reinforcement to the segment where such reinforcement is primarily needed. According to a first aspect of the invention there is provided a method of manufacturing a tunnel or shaft lining, or pipeline section of segments, wherein each segment comprises a concrete body having an extrados surface, an intrados surface and first and second ends and first and second sides, the ends and sides providing edge portions, the segments being adapted to be connected to further similar segments with edge portions adjacent edge portions of adjacent segments, the method being characterised in that the method includes enveloping the ends or sides of a least a pair of segments in a reinforcing material as the concrete is cast, and once the concrete has cured, connecting the segments together with one of each of their enveloped ends or sides adjacent, and sealing between the enveloped ends or sides. Thus the tunnel or shaft lining or pipeline is made of generally curved, segments which are each reinforced by external reinforcement material. Most conveniently the reinforcing material of each segment is provided by a pair of generally "C" or channel shaped reinforcing members each having an edge part which in use extends alongside an edge portion of the concrete body, and a pair of spaced generally parallel flanges which are integral with the edge part of the reinforcement member and in use each overlies a part of the infrados or exfrados surface and the method further includes making each of the segments by supporting a pair of reinforcing members generally parallel to but spaced from one another, and casting concrete into the space between the reinforcement members so that opposing edge portions of the concrete body thus formed, are enveloped by the reinforcement members. Thus there is no discontinuity in the reinforcing material along the reinforced sides or ends. If desired, usually largely for cosmetic reasons, and to facilitate the casting in concrete of the, usually curved, intrados or exfrados surfaces, at least one of an exfrados and intrados surface covering member is provided, which may be supported relative to the reinforcement members so as to form a cavity into which the concrete is cast. Such covering member will add little strength to the segment but will enable an exfrados and/or intrados surface of improved finish to be produced, thus reducing or even eliminating finishing work within the tunnel or shaft lining or pipeline, which otherwise may be required. Preferably a covering member is provided for both the intrados and exfrados surfaces, which covering members are supported relative to the reinforcement members during concrete casting, and if desired additional covering members may be provided for each of the sides or ends which are not enveloped by the reinforcement material. Thus the method may comprise supporting the additional covering members relative to the reinforcement members and the covering members for the intrados and exfrados surfaces, so as to form a substantially closed cavity, and introducing the concrete into the cavity through a passage provided in one of the covering or additional covering members under pressure. So that the reinforcement material enveloping the ends or sides of the segment can be made as thin, strong and light as possible, the reinforcement members are preferably made in a fibre reinforced plastic material, with fibres of the reinforcement extending generally along the reinforcement member. The reinforcement members may be made by pultmsion or another suitable method. The fibre reinforcement may comprise continuous filament mat and stitch bonded roving cloth and the plastic may comprise resin. During construction of the lining or pipeline, a sealing member may be located between adjacent enveloped ends or sides of a pair of segments, prior to the segments being connected or finally connected to one another. Thus the sealing member may be compressed between reinforcing material enveloping the adjacent ends or sides as the end or sides are connected together, although a hydrophilic kind of sealing member may altematively/additionally/integrally be provided. According to a second aspect of the invention we provide a method of manufacturing a lining segment comprising a concrete body having an exfrados surface, an intrados surface and first and second ends and first and second sides, the ends and sides providing edge portions, the segment being adapted to be connected to a further similar segment with an edge portion adjacent an edge portion of the further segment, the method being characterised in that the method includes enveloping the ends or sides of the segment in a reinforcing material as the concrete is cast, and permitting the concrete to cure. According to a third aspect of the invention e provide a lining segment comprising a concrete body having an exfrados surface, an intrados surface, first and second ends and first and second sides, the ends and sides providing edge portions, characterised in that the ends or sides are enveloped by reinforcing material. The reinforcing material of the segment of the third aspect of the invention may provided by a pair of edge reinforcement members each comprising a generally "C" or channel shape provided by an edge part which in use extends alongside an edge portion of the concrete body, and a pair of spaced generally parallel flanges which are integral with the edge part of the reinforcement member and in use each overlies a part of the infrados or exfrados surface. By virtue of the use of reinforcement members, the reinforced sides or ends of the segment may be made to other than simple plane shape. For example the edge part of one of the pair of the reinforcing members and the corresponding edge portion of the concrete body may include a male formation and the edge part of the other of the pair of reinforcing members and the corresponding edge portion of the concrete body may include a corresponding female formation, the male and female formations being adapted in use to inter- engage with corresponding female and male formations respectively of adjacent segments. Thus relative location of a pair of segments during lining construction is facilitated and to improve sealing between the adjacent segments, the edge part of at least one of the pair of the reinforcing .members and the corresponding edge portion of the concrete body, may include a recess formation. In use the recess formation together with an edge part of an adjacent segment may provide a cavity for receipt of a sealing member between the adjacent lining segments. Thus the problems of sealing between bare concrete surfaces with irregularities is overcome. The ends of the segment may be curved, following the profile of the intrados and exfrados surfaces and thus in use extending generally circumferentially of the lining or pipeline, and the sides may be generally straight and thus in use extend generally longitudinally of the lining or pipeline. The reinforcing material may envelope the ends of the concrete body and/or the sides of the concrete body. A covering member may be provided substantially to cover the exfrados and/or the intrados surface. The reinforcing material may comprise a fibre reinforced plastic material or similar, and the fibre reinforcement may comprise a continuous fibre mat and stitch bonded unidirectional roving cloth, and the plastic may comprise, resin. The reinforcing members may each be made by pultrusion, with the reinforcing fibres extending generally along the reinforcement member, or by moulding or another similar method. According to a fourth aspect of the present invention we provide a lining of a tunnel, shaft or pipeline comprising a plurality of lining segments according to the third aspect of the invention, connected together with reinforcement material enveloped edge portions of the segments lying adjacent other similarly enveloped edge portions. Embodiments of the invention will now be described, by way of example only, widi reference to the accompanying drawings in which: FIGURE 1 is an illusfrative view of part of a short section of tunnel lining made by a method according to the invention; FIGURE 2 is a cross section through line A-A in Figure 1, showing detail of a join between adjacent tunnel lining segments made by a method of a first embodiment; FIGURE 3 is a cross section through line A-A in Figure 1 showing a join between adjacent tunnel lining segments made by a method of a second embodiment, and FIGURE 4 is a detailed cross section through the reinforcing material of the embodiment of Figure 3. FIGURE 5 is an illusfrative view of a tunnel lining segment at a stage in manufacture. Referring to Figure 1 a tunnel lining 10 comprises a plurality of like curved tunnel segments 12. Each tunnel segment 12 is of an arched or curved shape and comprises a concrete body 11 which has an exfrados surface 13, an intrados surface 14, a first end 15, a second end 16, a first side 17 and a second side 18, each of the ends and sides comprising edge poifrons of the concrete body 11. The ends 15, 16, are arranged cuOumferentially in the tunnel and thus follow the curved profile of the infrados and exfrados surfaces 14, 13, while the sides 17, 18, are arranged longitudinally and are thus generally straight. In this arrangement, the ends 15, 16 and sides 17, 18 are enveloped in reinforcing material 19 which is provided by reinforcing members 19 which are generally "C" or channel shaped in cross-section although in another embodiment only the ends 15, 16 or the sides 17, 18 may be so enveloped. The ends 15, 16 and sides 17, 18 are enveloped in that the edge poifrons of the ends 15, 16 and sides 17, 18 of die body 11 are received within the reinforcing members 19 with an edge part 19a of the reinforcing member 19 extending alongside die respective end 15, 16 or side 17, 18 and integral flanges 19b, 19c overlapping peripheral poifrons of die infrados and exfrados surfaces 13, 14 of die body 11, as will be described more fully below so that die entire edge poifrons are enveloped. For a typical tunnel lining segment 12 die flanges 19b, 19c, extend 45mm onto the infrados and/or exfrados surfaces 13, 14. Referring to figure 5 particularly, each tunnel lining segment 12 is made using a mould support 40 to support a pair of reinforcmg members 19 generally parallel to one another and spaced apart, the space S between die pair 19 foiming a casting cavity. Although in figure 5, reinforcing members 19 for d e ends 15, 16 of die concrete body 11 only are shown, optionally, reinforcing members to reinforce the sides 17, 18 of the body 11 may also be supported by the support 40. hi each case there is no need to provide widiin die mould any additional reinforcement for the concrete as die concrete body 11 when casζ will obtain sufficient reinforcement solely from the external reinforcement members 19 which envelope the ends 15, 16 and/or sides 17, 18 of the concrete body 11. The casting cavity needs to be closed so tiiat die space between die pair or pairs of reinforcement members 19 can be filled with concrete. This may be achieved using suitable shuttering, or as indicated in figure 5, by providing coveiing members 41,42 for the infrados and exfrados suifaces 14,13, which coveiing members 41,42 become attached to the concrete and mus form part of d e segment 12. If desired, die coveiing members 41,42 may be secured to die reinforcement members 19 e.g. by an adliesive or may simply be supported relafrve to die reinforcement members 19 by die mould support 40. In such circumstances spars may be provided to span die exfrados or infrados surface coveiing members 41,42 during concrete casting, which spars will become enveloped in die concrete. Where only die ends 15, 16 or sides 17, 18 of die concrete body 11 are reinforced with reinforcement members 19, the non enveloped ends or sides may be covered by covering members 44, 45 wliich again may be attached to die reinforcement members 19 e.g. by adliesive prior to the concrete being cast, and become attached to die concrete. hi each case, the space S between die reinforcement members 19 is tiien filled with concrete such that die casting cavity provided by die reinforcing members 19 and any coveiing members is filled. Where die casting cavity is substantially closed by the reinforcement members 19 and coveiing members 41, 42, 44, 45, a passage P may need to be made in one or more of the coveiing members to permit the concrete to be introduced, preferably under pressure to ensure tiiat the concrete fills the cavity, there being air escape holes H provided where necessaiy to permit any air trapped by the concrete to escape. Thereafter me concrete may be appropriately treated to settle the contents, and the concrete allowed to cure. Thus the body portion 11 is formed within the reinforcing members 19, such that the ends 15, 16 and/or sides 17, 18 are enveloped at the time of manufacture. The concrete used may contain reinforcing elements, such as steel or glass fibres, within the pourable mix if so desired, aldiough preferably the reinforcing members 19 are designed to provide sufficient overall reinforcement. The mould support 40 may include a former of an appropriate material such as steel or wood, to ensure that the mould provided by die reinforcement members, coveiing members, shuttering etc. it does not twist, sag, or otherwise distort. A plurality of tunnel lining segments 12 are used to manufacture a tunnel lining by joining diem togedier end 15 to end 16 and side 17 to side 18 with further similar segments, as shown in Figure 1, to produce a circular lining 10. Thus reinforcing members 19 which envelope the ends 15, 16, provide cfrcumferential reinforcement and/or reinforcing members 19 which envelope die sides 17, 18 provide longitudmal reinforcement. Any appropriate form of connectors may be used to secure the segments 12 in place, for example connectors of die kind disclosed in British Patent No GB2131514. The reinforcing members 19 which envelope die ends 15, 16, or sides 17, 18 may provide mating surfaces as shown in figure 2 at 15a, 16a for die ends 15, 16. Referring to Figure 2 in particular in which part of a tunnel lining made by a first method in accordance widi d e invention is shown in detail. A first end 15 of one segment 12 is formed within a reinforcement member 19 widi a male formation 20 and a second end 16 of an adjacent similar segment 12 is formed within its reinforcement member 19 with a female formation 21. The male formation 20 and female formation 21 are adapted to inter-engage when die adjacent tunnel segments 12 are connected in use as shown in Figure 2. The male and female formations 20, 21 provide some level of sealing between die adjacent segments 12. hi addition they assist in accurate relative location of die tunnel segments 12 idi respect to each other during construction of the tunnel Idling 10. The ends 15, 16 further each comprise a recess 22 and 23 formed within die reiivforcement member 19. The recesses 22, 23 are adapted to cooperate widi each otiier to provide a cavity 24 inbetween the adjacent segments 12. The cavity 24 may receive a sealing means in the foπn of a compressible gasket 25 and/or a gasket of or containing hydrophilic material. Alternatively, die sealing means may take the form of sealant which cures or sets after being injected, or otherwise is introduced, into the cavity 24. If desired only one of die ends 15 or 16 may have a recess 22 or 23 which co-operates with a plain face of the opposing ends 16 or 15, but nevertheless forms a recess for a sealing means. Referring now to Figure 3, an alternative form of reinforcing member 19 is illustrated with 10<e parts to die reinforcing members 19 described in relation to figure 2 being like referenced, hi tiiis embodiment d e male and female formations are omitted, but the recesses 22, 23 for a sealing means are retained. Referring now to Figure 4 details of one form of die reinforcing member 19 particularly appropriate for die embodiment of Figure 3 is shown. The reinforcing member 19 comprises fibre reinforced plastic material in the form of a laminate. Two kinds of fibre are used, continuous filament mat (CFM) 30 typically of 300g/m 2 and stitch bonded unidirectional roving cloth (SBURC) 31 typically of 900g/m 2 . The density of die fibre elements of die laminate is not die same for all of die area of die reinforcing material 19, as can be seen in Figure 4. A central layer of SBURC 3 la, is surrounded by an intermediate layer of SBURC 3 lb in the flanges 19a, 19b and of CFM 30a in the web or edge part XX. An outer layer of CFM 30b surrounds the intermediate layer 31b and 30a. The fibres of the SBURC 31 is oriented longitudinally of the reinforcing material 19. hi one manufacturing mediod, die fibres of the laminate when laid up are immersed in an appropriate resin, for example Ciystic 701 P. A. in a mould, and may be subjected to vacuum to draw the resin and embedded fibres into the mould, but any appropriate alternative manufacturing technique may be used. For example the reinforcing member 19 may conveniently be made by pultrusion Where the reinforcing member 19 is for a curved end 15, 16, die reinforcement member 19 will need to be correspondingly curved, so as to follow die desired profile of the exfrados 13 and infrados 14 surfaces. Thus the fibres and resin would need to be moulded to an appropriate shape, preferably widi d e fibres following die desired curve. Although die embodiments described above incorporate enveloped ends and sides, embodunents according to die invention may incorporate only enveloped ends or only enveloped sides. The embodiments described above relate to tunnel linings made up of segments. However, die invention may also be applied to pipelines where the segments are often circular and therefore comprise ends but no sides, the pipeline being formed from a plurality of round segments being connected end to end. The features disclosed in die foregoing description die following claims or die accompanying drawings, expressed in tiieir specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, or a class or group of substances or compositions, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms tiiereof.

Claims: CLAIMS 1. A method of manufacturing a tunnel or shaft lining or pipeline of segments, wherein each segment comprises a concrete body having an exfrados surface, an infrados surface and first and second ends and first and second sides, the ends and sides providing edge portions, the segments being adapted to be connected to further similar segments with edge portions adjacent edge portions of adjacent segments, the method being characterised in that the method includes enveloping the ends or sides of a least a pair of segments in a reinforcing material as the concrete is cast, and once the concrete has cured, connecting the segments together with one of each of their enveloped ends or sides adjacent, and sealing between the enveloped ends or sides. 2. A method according to claim 1 characterised in that the reinforcing material of each segment is provided by a pair of generally channel shaped reinforcing members each having an edge part which in use extends alongside an edge portion of the concrete body, and a pair of spaced generally parallel flanges which are integral with the edge part of the reinforcement member and in use each overlies a part of the intrados or extrados surface and the method further includes making each of the segments by supporting a pair of reinforcing members generally parallel to but spaced from one another, and casting concrete into the space between the reinforcement members so that opposing edge portions of the concrete body thus formed, are enveloped by the reinforcement members. 3. A method according to claim 1 or claim 2 characterised in that at least one of an extrados and intrados surface coveiing member is provided, which is supported relative to the reinforcement members so as to form a cavity into which the concrete is cast. 4. A metiiod according to claim 3 characterised in that a covering member is provided for both the intrados and extrados surfaces, which covering members are supported relative to the reinforcement members are relative to each other during concrete casting. 5. A method according to claim 4 characterised in that additional covering members are provided for each of the sides or ends which are not enveloped by die reinforcement material, and the method comprises supporting the additional coveiing members relative to the reinforcement members and the covering members for the intrados and extrados surfaces, so as to form a substantially closed cavity, and introducing the concrete into die cavity through a passage provided in one of the covering or additional covering members under pressure. 6. A method according to any one of claims 1 to 5 characterised in that the method includes making the reinforcement members in a fibre reinforced plastic material, with fibres of the reinforcement extending generally along the reinforcement member. 7. A method according to claim 6 characterised in that the reinforcement members are made by pultrusion. 8. A method according to claim 6 or claim 7 characterised in that the fibre reinforcement comprises continuous filament mat and stitch bonded roving cloth and the plastic comprises resin. 9. A method of according to any one of the preceding claims characterised in that a sealing member is located between adjacent enveloped ends or sides of a pair of segments, prior to the segments being connected or finally connected to one another. 10. A method according to claim 9 characterised in that the sealing members is compressed between reinforcing material enveloping the adjacent ends or sides as the end or sides are connected together. 11. A method of manufacturing a lining segment comprising a concrete body having an exfrados surface, an intrados surface and first and second ends and first and second sides, the ends and sides providing edge portions, the segment being adapted to be connected to a further similar segment with an edge portion adjacent an edge portion of the further segment, the method being characterised in that the method includes enveloping the ends or sides of the segment in a reinforcing material as the concrete is cast, and permitting the concrete to cure. 12. A lining segment comprising a concrete body having an extrados surface, an intrados surface, first and second ends and first and second sides, the ends and sides being provided by edge portions, characterised in that the ends or sides are enveloped by reinforcing material. 13. A segment according to claim 12 characterised in that the reinforcing material is provided by a pair of edge reinforcement members each comprising a generally channel shape provided by an edge part which in use extends alongside an edge portion of the concrete body, and a pair of spaced generally parallel flanges which are integral with the edge part of the reinforcement member and in use each overlies a part of the intrados or extrados surface. 14. A segment according to claim 13 characterised in that the edge part of one of the pair of the reinforcing members and the adjacent edge portion of the concrete body includes a male fonnation and the edge part of the other of the pair of reinforcing members and the adjacent edge portion of the concrete body includes a coιτesponding female fonnation, the male and female formations being adapted in use to inter-engage with coiτesponding female and male formations respectively of adjacent curved segments. 15. A segment according to claim 13 or claim 14 characterised in that tire edge part of at least one of the pair of the reinforcing members and the corresponding edge portion of the concrete body includes a recess fonnation, in use the recess fonnation together with an edge part of an adjacent segment providing a cavity for receipt of a sealing member between the adjacent lining segments. 16. A segment according to any one of claims 12 to 15 characterised in that the ends are curved, following the profile of the intrados and extrados surfaces, and the sides are generally straight, the reinforcing material enveloping the ends of the concrete body. 17. A segment according to any one of claims 12 to 16 characterised in that the ends are curved, following the profile of the intrados and extrados surfaces, and the sides are generally straight, the reinforcing material enveloping the sides of the concrete body. 18. A segment according to any one of claims 12 to 17 characterised in that an exfrados surface coveiing member substantially covers die exfrados surface. 19. A segment according to any one of claims 12 to 18 characterised in that an intrados surface covering member substantially covers the infrados surface * . 20. A segment according to any one of claims 12 to 19 characterised in mat the reinforcing material comprises a fibre reinforced plastic material. 21. A segment according to claim 20 characterised in that the fibre reinforced plastic material comprises a continuous fibre mat and stitch bonded unidirectional roving cloth, and resin. 22. A segment according to any one of claims 13 to 21 where appendent to claim 13 characterised in that the reinforcing members are each made by pultrusion, with the reinforcing fibres extending generally along the reinforcement member. 23. A lining of a tunnel, shaft or pipeline comprising a plurality of lining segments according to any one of claims 12 to 22, connected together with reinforcement material enveloped edge portions of the segments lying adjacent other similarly enveloped edge portions. 24. A lining of a tunnel, shaft or pipeline substantially as hereinbefore described with reference to and as shown in the accompanying drawings. 25. A method of manufacturing a tunnel, shaft or pipeline substantially as hereinbefore described with reference to the accompanying drawings. 26. -A method of manufacturing a lining segment substantially as hereinbefore described with reference to the accompanying drawings. 27. A lining segment substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

Inventors: GIMBERT ALAN WILLIAM, GIMBERT, ALAN, WILLIAM
Applicants: GIMBERT ALAN WILLIAM, TARMAC UK LTD, GIMBERT, ALAN, WILLIAM, TARMAC HEAVY BUILDING MATERIALS UK LIMITED
Application year: 1998
Main classification: E21D11
IPC codes: E21D11