Abstract:
A rehabilitating pipe is laid inside an existing pipe to rehabilitate the existing pipe. Support members are intergrally connected to an inner wall surface of the existing pipe so that loop portions of the respective support members extend from the inner wall surface of the existing pipe. The rehabilitating pipe is assembled inside of the existing pipe by mutually coupling segments of the rehabilitating pipe in a longitudinal direction of the existing pipe by inserting coupling members through connecting through-holes of the segments and through the loop portions of the respective support members to thereby support the assembled rehabilitating pipe so that the rehabilitating pipe remains inside of the existing pipe after assembly to rehabilitate the existing pipe.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a method for laying a rehabilitating pipe wherein a rehabilitating pipe is laid inside an existing pipe such as a sewer pipe to rehabilitate the existing pipe. 
   2. Description of the Prior Art 
   A method of rehabilitating an existing pipe is known, for example, from Japanese Patent Laid Open Publication No. 2003-286742 in which an existing pipe such as a sewer pipe is rehabilitated using a rehabilitating pipe whose outer diameter is slightly less than the inner diameter of the existing pipe. A filler is filled and hardened in a gap between the outer periphery of the rehabilitating pipe and the inner wall surface of the existing pipe to construct a compound pipe comprising the rehabilitating pipe, the filler, and the existing pipe. The rehabilitating pipe is assembled by coupling segments in the circumferential direction and the longitudinal direction of the pipe. One segment corresponds to a block shaped member obtained by segmenting the rehabilitating pipe in its circumferential and longitudinal directions of the pipe. 
   Due to its own weight and the weight of the filler filled after assembly, the assembled rehabilitating pipe unfortunately deforms into a distorted shape so that it breaks in the downward direction if left as is. Conventionally, various methods have been employed as countermeasures, such as to increase the thickness and strength of the segments; to accessorily provide steel reinforcing rods in a ring shape around the outer periphery of the rehabilitating pipe; and, before filling with the filler, to install inside the rehabilitating pipe supports, such as struts, at intervals of several meters in the longitudinal direction. 
   In addition, at a position where the outer periphery of the lower end of the rehabilitating pipe contacts the bottom of the existing pipe, it is necessary to position the center of the rehabilitating pipe so that it is directly below the center of the existing pipe; however, because the specific gravity of the rehabilitating pipe is less than that of the filler, the rehabilitating pipe unfortunately floats above the aforementioned position if left as is. To avoid this, spacers are conventionally inserted from the left and right of the rehabilitating pipe between the outer periphery of the upper side of the rehabilitating pipe and the inner wall surface of the existing pipe, and pressed so that the rehabilitating pipe does not float upwards, thus positioning the rehabilitating pipe at the aforementioned position. 
   If the segments are made thicker, then there is a problem in that the weight of the segments increase, thus increasing the burden on the workers performing the assembly of the rehabilitating pipe; in addition, the amount of resin filled in the segments also increases, thus unfortunately leading to a cost increase. In addition, there is a problem in that the work involved in the method of accessorily providing steel reinforcing rods in a ring shape is extremely troublesome and time consuming. In addition, there is also a problem in that, in the method of installing the supports, the supports hinder the workers who move inside the narrow rehabilitating pipe when performing the work of filling with the filler, thus degrading working efficiency; in addition, it is necessary to perform the work of removing the supports after hardening of the filler. In addition, the deformation of the rehabilitating pipe cannot be prevented just with the method that presses down on the upward rise of the rehabilitating pipe with spacers, and it is consequently unfortunately necessary to also use, in parallel, one of the aforementioned methods of preventing deformation. 
   It is therefore an object of the present invention to provide a method for laying a rehabilitating pipe wherein the deformation and upward rising of the rehabilitating pipe can be prevented, and wherein the work of laying the rehabilitating pipe can be performed more simply and in a shorter period of time with the weight and cost of the segments reduced. 
   SUMMARY OF THE INVENTION 
   In a method for laying a rehabilitating pipe inside an existing pipe according to the present invention, segments are mutually coupled in the circumferential and longitudinal directions of the existing pipe to assemble the rehabilitating pipe. The method comprises the steps of fixing supporting members each having a hole to an inner wall surface of the existing pipe; and coupling the segments in the longitudinal direction of the existing pipe using a rod-shaped coupling member. The coupling member is inserted through the segment in the longitudinal direction and through the hole of the supporting member to thereby support the assembled rehabilitating pipe inside the existing pipe. 
   The method of the present invention can prevent deformation of the rehabilitating pipe due to its own weight and the weight of the filler, and can prevent the floating up of the rehabilitating pipe when filling with the filler because the rehabilitating pipe being assembled is supported during coupling of the segments in the longitudinal direction by the supporting members, which are previously fixed to the inner wall surface of the existing pipe. Accordingly, superior effects are obtained in that the thickness, weight, and cost of the segments are reduced; in addition, the work of laying the rehabilitating pipe can be performed more simply and in a shorter period of time because it suffices to just fix the supporting members to the inner wall surface of the existing pipe beforehand, and it is unnecessary to accessorily provide steel reinforcing rods for reinforcement or to install supports to prevent deformation. 
   Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and following detailed description of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view showing a partially schematic section of a segment used in laying a rehabilitating pipe in an embodiment of the present invention. 
       FIG. 2  is a perspective view showing how the segments are coupled in the circumferential direction and in the longitudinal direction. 
       FIG. 3  is a longitudinal cross sectional view taken along the circumferential direction of the coupling members showing how the segments are mutually coupled in the circumferential direction. 
       FIG. 4  is a radial cross sectional view taken along the longitudinal direction showing how the segments are mutually coupled by coupling members in the longitudinal direction. 
       FIG. 5  is a partial broken perspective view showing how the segments are coupled inside the existing pipe to assemble a rehabilitating pipe. 
       FIG. 6  is a cross sectional view orthogonal to the longitudinal direction showing how anchor rings are fixed to the inner wall surface of the existing pipe. 
       FIG. 7  is a planar view showing the structure of the anchor ring and the anchor bolt for fixing such. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The present invention will be described based on preferred embodiments, referring to the drawings in which a round rehabilitating pipe is shown whose cross sectional shape orthogonal to the longitudinal direction is round; however, it is understood that the method of the present invention can also be applied even to the laying of a rehabilitating pipe having another shape, such as a rectangle. 
   An existing pipe  4  such as a round sewer pipe is rehabilitated using a rehabilitating pipe  3  whose outer diameter is a prescribed amount less than the inner diameter of the existing pipe  4 , as shown in  FIG. 5 . The rehabilitating pipe  3  is laid inside the existing pipe  4  by coupling segments  1  in the circumferential and longitudinal directions of the existing pipe  4 . 
   One segment  1  serves as an assembly unit for the rehabilitating pipe  3  and, as shown in  FIG. 1 , comprises an inner plate  101 , side plates  102  and  103 , end plates  104  and  105 , and respectively two each of reinforcing plates  106  and  107 . These plates  101  through  107  are integrally molded from a transparent, semitransparent, or opaque plastic to provide one segment. Vinyl chloride, ABS, DuraStar polymer (trade name), and the like are used as the transparent plastic. PVC, polyethylene, and the like are used as the semitransparent plastic. PVC, polyester, ABS, polyethylene, polypropylene, and the like are used as the opaque plastic. 
   The inner plate  101  is formed as a plate having a prescribed width and is arcuately curved at a prescribed angle that divides the circumference into a plurality of equal parts, e.g., 72 °  (five parts). The bottom surface of the inner plate  101  corresponds to the inner circumferential surface of the rehabilitating pipe with the circumferential direction of the arc corresponding to the circumferential direction of the rehabilitating pipe and the latitudinal direction of the arc to the longitudinal direction thereof. A plurality of rectangular openings  101   a  is formed respectively on both end parts of the inner plate  101  for performing from the inside the work to mutually couple the segments  1  in the circumferential direction. 
   The side plates  102  and  103  are formed at both side edges along the circumferential direction of the inner plate  101 , and are provided upright outwardly at a prescribed height on the top surface of the inner plate  101 . A plurality of connecting through holes  102   a  and  103   a  (herein, 14) (second connecting holes) is formed in each of the side plates  102  and  103  at a prescribed interval in the circumferential direction for passing therethrough coupling members in the longitudinal direction, as discussed later. 
   The connecting plates  104  and  105  (hereinafter “end plates”) are formed at both end edges of the inner plate  101  along the longitudinal direction thereof, and are provided upright outwardly on the top surface of the inner plate  101  at a height the same as each of the side plates. Through holes  104   a  and  105   a  (first connecting holes) are formed at a plurality of locations in the end plates  104  and  105  for passing therethrough bolts that mutually couple the segments  1  in the circumferential direction (refer also to  FIG. 3 ). 
   The reinforcing plates  106  and  107  serve to reinforce the mechanical strength of the entire segment  1 , and are provided upright outwardly at a prescribed height on the top surface of the inner plate  101  on the inner sides of the side plates  102  and  103 . In the reinforcing plates  106  and  107  are formed a plurality of through holes  106   a  and notched parts  107   a  for inserting therethrough the coupling members in the longitudinal direction at a position respectively corresponding to the through holes  102   a  and  103   a  of the side plates  102  and  103 . 
   In addition, laterally projecting, small, right triangular protruding plates  103   b ,  106   b  and  107   b  (the protruding plates of the side plate  102  are not shown) are formed at a plurality of locations on the inside surfaces of the side plates  102  and  103  and both side surfaces of the reinforcing plates  106  and  107  to prevent deformation respectively thereof, thereby forming a rib structure that enhances the strength of the segment  1 . 
   When the existing pipe to be repaired is circular in cross sectional shape, the segment  1  corresponds to a block obtained when a circular pipe with outer and inner circumference curvatures respectively corresponding to that of the existing pipe is cut off in round slices at a prescribed width, and the thus sliced pipe is segmented in the circumferential direction for division into parts (preferably into equal parts). 
   The number of reinforcing plates or the number of protruding plates can be varied in accordance with the required strength of the segment; if strong, then some or all can be omitted. In addition, the segment functions as a rehabilitating or repairing unit, so that it is not limited to an arcuate type or fan type as shown in  FIG. 1 , and can be made as a parallelepiped in accordance with the cross sectional shape or size of the existing pipe or the repair location of the existing pipe, and can also be made as a shape bent into a rounded right angle. 
   The segments are successively coupled in the circumferential direction with the outer surfaces of every end plate of each segment mutually aligned and also the inner surfaces of every inner plate thereof mutually aligned. The segments are also successively coupled in the longitudinal direction so that the outer surfaces of every side plate of each segment are mutually aligned and the inner surfaces of each inner plate are mutually aligned. Thus processes allow a rehabilitating pipe to be assembled with the inner entire surface thereof being uniform without any gap between the segments. 
   The following explains the details of a method for laying a rehabilitating pipe inside an existing pipe using the segments. 
   First, before assembling the rehabilitating pipe, anchors are fixed to the inner wall surface of the existing pipe  4 , as shown in  FIG. 6 . Each anchor serves as a support or supporting member that supports the rehabilitating pipe in order to prevent the deformation and floating up of the rehabilitating pipe. As shown in  FIG. 7 , the anchor comprises an end forming a closed loop portion, such as in the form of an anchor ring  8  having an elliptical hole  8   a  and a screw part  8   b , and an anchor bolt  9  having a screw hole  9   a , slits  9   b  and recessed parts  9   a  with a tapered member  9   d  inserted through the anchor bolt at the tip thereof. A hole is drilled in the inner wall surface of the exiting pipe  4  and the anchor bolt  9  is inserted and driven into the hole. As the tapered member  9   d  is pressed in, the structure of the slits  9   b  and recessed parts  9   a  allows the anchor bolt  9  to expand at the tip in the radial direction to jam into the hole. This allows the anchor bolt  9  to be fixed to the inner wall surface of the existing pipe  4 . By screwing the screw part  8   b  of the anchor ring  8  into the screw hole  9   a  of the anchor bolt  9 , the anchor ring  8  can also be fixed to the inner wall surface of the existing pipe  4 . 
   The anchor rings  8  and anchor bolts  9  are fixed at a plurality of positions at an appropriate interval (for example, one to several meters) in the longitudinal direction on the inner wall surface across the length of the existing pipe  4  and are also fixed at a plurality of positions (herein, four positions, two each at the upper end and the lower end) at an appropriate angular interval in the circumferential direction of the existing pipe  4 , as shown in  FIG. 6 . 
   The fixing positions of the anchor are selected such that a coupling member  11  for coupling the segments in the longitudinal direction can pass through the holes  8   a  of the anchor ring  8  (refer to  FIG. 4 ). In addition, the anchor rings  8  are fixed so that the long axis direction of the ellipse of the hole  8   a  follows the circumferential direction of the existing pipe  4 . In addition, by varying the extent to which the screw part  8   b  of the anchor ring  8  is screwed into the screw hole  9   a  of the anchor bolt  9 , the position of the hole  8   a  of the anchor ring  8  can be adjusted in the radial direction of the existing pipe  4 . The fixing position in the longitudinal direction of the anchor ring  8  is also set to such a position at which, for example, as shown in  FIG. 4 , it does not contact the side plates  102  and  103  and the reinforcing plates  106  and  107  of the segment  1 , e.g., at a position between the reinforcing plates  106  and  107 . 
   Furthermore, because a rod  11   b  of the coupling member  11  is inserted through the elliptical hole  8   a  of the anchor ring  8 , it is understood that the diameter in the short axis direction, and of course the diameter in the long axis direction, is greater than the diameter of the rod  11   b.    
   In addition, the anchor rings  8  are fixed at all fixing positions before the assembly of the rehabilitating pipe; however, every time the rehabilitating pipe is assembled by a length corresponding to the interval of the successive fixing positions of the anchor rings  8  in the longitudinal direction, it is also acceptable to fix anchor rings  8  on the inner wall surface of the existing pipe  4  at positions corresponding to the segments  1  to be coupled next in the longitudinal direction, and then subsequently perform the next coupling of the segments in the longitudinal direction. 
   After the anchor rings  8  have been fixed, the segments  1  are carried into the existing pipe, and successively coupled in the circumferential direction, as shown in  FIG. 2 . This coupling is performed, as shown in detail in  FIG. 3 , by positioning each segment  1  so that the inner plates  101  and the side plates  102  and  103  of the segments align mutually; tightly sealing the outer surfaces of the end plates  104  and  105  of the segments  1 ; inserting connecting members, such as bolts  6 , into the through holes  104   a  and  105   a  from the opening  101   a  of the inner plate  101 ; screwing on nuts  7 ; and tightening both end plates  104  and  105 . 
   Furthermore, recessed parts  104   b  and  104   c  are formed across the entire length of the end plate  104  in the longitudinal direction, and protruding parts  105   b  and  105   c , which respectively interfit with those recessed parts, are formed across the entire length of the end plate  105  in the longitudinal direction, thereby facilitating the work of positioning and tightly sealing both segments during coupling. In addition, by coating the interfitted part with a sealing material (not shown) beforehand, the watertightness of the coupled parts can be enhanced. In addition, when the coupling is completed, a cover (not shown) and the like is used to tightly seal each opening  101   a . At this time, the inner surface of the cover is made continuous with the inner surface of each inner plate, thus forming a uniform inner surface. 
   At the positions where the anchor rings  8  are fixed, they become a hindrance, so that the segments are successively coupled in units (unit coupling). At other positions the segments are coupled until they form a ring (ring coupling). 
   After the segments are coupled into a ring or after a prescribed number of segments are coupled in the circumferential direction, other segments  1 ′ are coupled in the longitudinal direction to the already coupled segments, as shown in  FIG. 2 . 
   The coupling in the longitudinal direction is performed, as shown in  FIG. 4 , by using a rod shaped coupling member  11  made of metal and that integrally joins a rod  11   b  with one end thereof formed as a screw part  11   a , and the other end as a nut part  11   c . A screw hole  11   d  is formed in the nut part  11   c  to receive the screw part  11   a  of the rod of another coupling member. 
   In  FIG. 4 , the coupling member  11  on the right side is already joined to the nut part  11   c  of another coupling member, shown by the chain line, and fixed to the segment  1 . To couple another segment  1 ′ to this segment  1 , both segments  1  and  1 ′ are first positioned so that the inner surfaces of the inner plates  101  thereof align and form a uniform surface. The outer surfaces of the side plates  102  and  103  of both the segments are then brought into tightly contact with each other with the nut part  11   c  protruding from the side plate  102  of the segment  1  interfitted with a through hole  103   a  of the side plate  103  of the segment  1 ′. 
   A coupling member  11 ′ is then inserted through from the through hole  102   a  of the side plate  102  of the segment  1 ′, and the screw part  11   a ′ thereof is screwed into the screw hole  11   d  of the nut part  11   c  of the coupling member  11 . At this time, the screw part  11   a ′ and a rod  11   b ′ are inserted from the through hole  102   a  through the through hole  106   a , two notched parts  107   a , and the through hole  106   a , and screwed in; however, as shown in the figure, the anchor ring  8  is fixed facing the insertion position, and the screw part  11   a ′ and the rod  11   b ′ are also inserted through the hole  8   a  if the position of the hole  8   a  is aligned with the insertion position. 
   Upon screwing the screw part  11   a ′ into the screw hole  11   d  until a nut part  11   c ′ of the coupling member  11 ′ hits against the reinforcing plate  106  of the segment  1 ′, the coupling member  11 ′ clamps the segment  1 ′ against the segment  1  to thereby couple both segments  1  and  1 ′. Because the coupling of every segment is performed using, for example, four coupling members per segment, both segments  1  and  1 ′ are coupled rigidly in the longitudinal direction. The coupled segments  1  and  1 ′ are supported by anchor rings  8  via the coupling member  11 ′ inserted through the hole  8   a  of the anchor rings  8 . 
   Furthermore, since a protruding line  102   c  and a recessed line  103   c  that interfits thereto are formed across the entire perimeter in the circumferential direction of each side plate, the work of positioning and tightly sealing both segments during coupling in the longitudinal direction is simplified, the same as coupling the circumferential direction; in addition, by coating the interfitting part with a sealing material (not shown) beforehand, the watertightness of the coupled parts can be enhanced. 
   In addition, when the segment  1  in  FIG. 4  is the initial segment in the longitudinal direction, the coupling member as shown in the figure cannot be used, and therefore a fixing member having a structure the same as the nut part  11   c  that can fix the segment  1  by some means is used as the coupling member. 
   As described above, the rehabilitating pipe  3  can be assembled and laid by successively and mutually coupling segments  1  in the circumferential and longitudinal directions inside the existing pipe  4 , as shown in  FIG. 5 . In this assembly, the coupling members are used to couple the segments in the longitudinal direction and inserted through the anchor rings, which are fixed at a plurality of positions at an appropriate interval on the inner wall surface of the existing pipe  4 . This allows the assembled rehabilitating pipe  3  to be assuredly supported at a plurality of positions inside the existing pipe by the anchor rings  8  with the aid of the coupling member  11 . 
   Furthermore, because the rehabilitating pipe  3  is tentatively positioned by the support of the anchor rings  8  and cannot necessarily be positioned accurately, the rehabilitating pipe  3  is also positioned, as needed, by the use of other means in parallel, such as inserting spacers (not shown) between the outer periphery of the rehabilitating pipe  3  and the inner wall surface of the existing pipe  4 . 
   After completion of the pipe laying, the gap between the existing pipe  4  and each of the segments  1  of the rehabilitating pipe  3  is filled with the filler (not shown), and integrated with the existing pipe as a compound pipe. The rehabilitating pipe  3  is supported in the vertical direction by the anchor rings  8  at a plurality of positions, as mentioned above, so that it is possible to prevent deformation due to the self-weight of the rehabilitating pipe  3  and the weight of the filler, and also to prevent the floating up of the rehabilitating pipe  3  in the filler. 
   In  FIG. 5  the coupled segments  1  are schematically depicted as a simple block shape, and only one reinforcing plate is shown for the segments  1  wherein an anchor ring  8  and coupling members  11  are illustrated and the positions of other anchor rings  8  and the insertion positions of other coupling members  11  are depicted by chain lines. Although all of the segments  1  in  FIG. 5  are coupled with their end plates aligned in the longitudinal direction, they can also be coupled with the positions of the end plates offset. In addition, it is understood that the number of coupling members  11  inserted per segment  1  is not limited to four. 
   The above successively couples the segments at only one side of the existing pipe in the longitudinal direction (single sided coupling), but it is also possible to successively couple at both sides in the longitudinal direction (bilateral coupling). In this case, the pipe laying time can be reduced because the segments can be coupled from both sides. 
   According to the embodiments described above, the work of laying the rehabilitating pipe can be performed more simply and in a shorter period of time because the thickness, weight, and cost of the segments  1  are reduced, and because, just by fixing the anchor rings  8  in advance to the inner wall surface of the existing pipe  4 , it is unnecessary to accessorily provide steel reinforcing rods for reinforcement, as is done conventionally, or to install supports to prevent deformation. 
   Furthermore, the embodiments explained above make the holes  8   a  elliptical in order to handle the offset in the insertion positions of the coupling members  11 ; however, if that offset can be decreased, it is also acceptable to make the holes  8   a  circular, and to make their radii close to the rods  11   b  of the coupling members  11 . In addition, it is understood that the holes  8   a  can also be formed with other shapes in accordance with the cross sectional shape of the rod  11   b.