U.S. patent application number 13/237311 was filed with the patent office on 2012-05-17 for systems and methods for providing a concrete-reinforced bore.
Invention is credited to Zi Li FANG, George David RICHARDSON.
Application Number | 20120121337 13/237311 |
Document ID | / |
Family ID | 45874441 |
Filed Date | 2012-05-17 |
United States Patent
Application |
20120121337 |
Kind Code |
A1 |
RICHARDSON; George David ;
et al. |
May 17, 2012 |
SYSTEMS AND METHODS FOR PROVIDING A CONCRETE-REINFORCED BORE
Abstract
Systems and methods are provided for constructing a lined
reinforcement structure that covers a portion of an interior wall
of a bore. A plurality of axial lining segments; and a bracing
station axially moveable along the bore are provided. The bracing
station comprises formwork component(s) coupled to brace
mechanism(s) for bracing the formwork components against inwardly
directed forces the brace mechanism(s) moveable between extended
configurations wherein the formwork component(s) are closer to the
interior bore wall and retracted configurations wherein the
formwork components are further from the interior bore wall.
Inventors: |
RICHARDSON; George David;
(Vancouver, CA) ; FANG; Zi Li; (New Westminster,
CA) |
Family ID: |
45874441 |
Appl. No.: |
13/237311 |
Filed: |
September 20, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61384703 |
Sep 20, 2010 |
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Current U.S.
Class: |
405/150.1 |
Current CPC
Class: |
E21B 43/10 20130101;
E21D 11/102 20130101; E21D 11/105 20130101 |
Class at
Publication: |
405/150.1 |
International
Class: |
E21D 11/00 20060101
E21D011/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 20, 2010 |
CA |
2714763 |
Claims
1. A method for providing a lined reinforcement structure that
covers at least a portion of an interior wall of a bore, the method
comprising: (a) providing a plurality of axial lining segments; (b)
providing a bracing station axially moveable along the bore, the
bracing station comprising one or more formwork components coupled
to one or more brace mechanisms for bracing the formwork components
against forces directed inwardly from the interior bore wall, the
one or more brace mechanisms moveable between extended
configurations wherein the formwork components are closer to the
interior bore wall and retracted configurations wherein the
formwork components are further from the interior bore wall; (c)
engaging one of the lining segments with the bracing station such
that the one of the lining segments moves axially along the bore
with the bracing station; (d) moving the bracing station and the
one of the lining segments axially along the bore to a desired
axial location; (e) fabricating a reinforcement structure segment
by introducing liquid concrete into at least a portion of a space
between the interior bore wall and the one of the lining segments;
(f) anchoring the one of the lining segments to the reinforcement
structure segment; (g) after the concrete cures, decoupling the
bracing station from the one of the lining segments such that the
bracing station is axially moveable within the bore independently
of the one of the lining segments; and (h) repeating steps (c)
through (g) until the reinforcement structure is fabricated.
2. A method according to claim 1 wherein: each of the one or more
brace mechanisms is coupled to a corresponding one of the one or
more formwork components; movement of each of the one or more brace
mechanisms to its extended configuration comprises locating its
corresponding formwork component at a location that is closer to
the interior bore wall; and movement of each of the one or more
brace mechanisms to its retracted configuration comprises locating
its corresponding formwork component at a location that is further
from the interior bore wall.
3. A method according to claim 1 wherein engaging the one of the
lining segments with the bracing station comprises moving the one
or more brace mechanisms from their retracted configurations to
their extended configurations.
4. A method according to claim 3 wherein moving the one or more
brace mechanisms from their retracted configurations to their
extended configurations comprises deforming at least a portion the
one of the lining segments, such that resilient deformation forces
tend to couple the one of the lining segments to the bracing
station.
5. A method according to claim 3 wherein moving the one or more
brace mechanisms from their retracted configurations to their
extended configurations comprises causing the formwork components
of the brace station to exert pressure on the one of the lining
segments to thereby form a pressure fit between the formwork
components and the one of the lining segments.
6. A method according to claim 1 wherein anchoring the one of the
lining segments to the reinforcement structure segment comprises
extending one or more anchors from the one of the lining segments
toward the interior bore wall before the concrete is permitted to
cure in the space between the interior bore wall and the one of the
lining segments.
7. A method according to claim 1 wherein for each of second and
subsequent iterations of steps (c) through (g), moving the bracing
station and the one of the lining segments axially along the bore
to the desired axial location comprises moving the bracing station
and the one of the lining segments until a leading edge of the one
of the lining segments abuts against a trailing edge of a
previously installed one of the lining segments.
8. A method according to claim 1 wherein each of second and
subsequent iterations of steps (c) through (g) comprises
fabricating second and subsequent reinforcement structure segments
such that transitions between axially adjacent reinforcement
structures are axially offset from transitions between axially
adjacent lining segments.
9. A method according to claim 8 wherein the transitions between
axially adjacent reinforcement structures are axially offset from
the transitions between axially adjacent lining segments by an
axial offset that is greater than 5% of an axial dimension of the
lining segment.
10. A method according to claim 1 wherein, for at least some of the
iterations of steps (c) through (g), anchoring the one of the
lining segments to the reinforcement structure segment comprises,
before the concrete is permitted to cure in the space between the
interior bore wall and the one of the lining segments: extending
one or more anchors from the one of the lining segments toward the
interior bore wall; and coupling the one or more anchors to the one
of the lining segments such that at least a subset of the one or
more anchors extends axially beyond a trailing edge of the one of
the lining segments to facilitate coupling the subset of the one or
more anchors to an axially adjacent lining segment on a next
iteration of steps (c) through (g).
11. A method according to claim 10 wherein coupling the one or more
anchors to the one of the lining segments such that the subset of
the one or more anchors extends axially beyond the trailing edge of
the one of the lining segments comprises providing the subset of
the one or more anchors with a variety of different axial extension
lengths beyond the trailing edge of the one of the lining
segments.
12. A method according to claim 1 comprising providing a working
platform which is couplable the bracing station to support workers,
thereby allowing the workers to perform work in the bore.
13. A method according to claim 12 comprising moving the working
platform axially along the bore independently of the bracing
station.
14. A method according to claim 1 comprising assembling one or more
reinforcement bar lattices which are encased in the concrete of the
reinforcement structure and wherein the one or more reinforcement
bar lattices extend axially across a transition between two or more
axially adjacent reinforcement structure segments.
15. A method according to claim 1 comprising assembling one or more
reinforcement bar lattices which are encased in the concrete of the
reinforcement structure and wherein the one or more reinforcement
bar lattices extend axially across a transition between two or more
axially adjacent lining segments.
16. A method according to claim 1 comprising fabricating a
secondary reinforcement structure inside a bore defined by the
reinforcement structure wherein fabricating the secondary
reinforcement structure comprises, after performing a first
iteration of the steps (a) through (h) to complete the
reinforcement structure, performing a second iteration of the steps
(a) through (h) to fabricate the secondary reinforcement structure,
while replacing the interior bore wall of the first iteration steps
(a) through (h) with an interior surface of a lining defined by the
lining segments of the reinforcement structure.
17. A method according to claim 16 wherein the lining defined by
the lining segments of the reinforcement structure is fabricated
from a material to which the concrete of the secondary
reinforcement structure does not bond.
18. A method according to claim 17 wherein the lining defined by
the lining segments of the reinforcement structure is fabricated
from a material that is sufficiently smooth to permit relative
slidable movement between concrete of the secondary reinforcement
structure and the lining under seismic activity.
19. A method according to claim 16 comprising assembling one or
more reinforcement bar lattices which are encased in the concrete
of the secondary reinforcement structure and wherein the one or
more reinforcement bar lattices extend axially across a transition
between two or more axially adjacent reinforcement structure
segments of the secondary reinforcement structure.
20. A system for providing a lined reinforcement structure that
covers at least a portion of an interior wall of a bore, the system
comprising: a plurality of axially extending lining segments; a
bracing station shaped for axial movement along the bore, the
bracing station comprising one or more formwork components coupled
to one or more brace mechanisms for bracing the formwork components
against forces directed inwardly from the interior bore wall, the
one or more brace mechanisms moveable between extended
configurations wherein the formwork components are closer to the
interior bore wall and retracted configurations wherein the
formwork components are further from the interior bore wall,
wherein bracing station is configured to engage one of the axial
lining segments when its brace mechanisms are in their extended
configurations such that the one of the axial lining segments moves
axially along the bore with the bracing station and to release, and
to move independently of, the one of the axial lining segments when
its brace mechanisms are in their retracted configurations; and an
axial movement mechanism to move the bracing station axial within
the bore.
21. A system according to claim 20 wherein the bracing station is
operable to engage the one of the lining segments, and the axial
movement mechanism is operable to move the bracing station and the
one of the lining segments axially along the bore to a desired
axial location whereupon a corresponding reinforcement structure
segment is fabricated by introducing liquid concrete into a space
between the interior bore wall and the one of the lining segments
and allowing the concrete in the space to cure.
22. A system according to claim 21 wherein the bracing station is
operable to release, and move axially within the bore independently
of, the one of the lining segments once the concrete of the
reinforcement structure segment cures by adjusting the one or more
brace mechanisms to their retracted configurations.
23. A system according to claim 20 wherein each of the one or more
brace mechanisms is coupled to a corresponding one of the one or
more formwork components such that movement of each of the one or
more brace mechanisms to its extended configuration positions its
corresponding formwork component at a location that is closer to
the interior bore wall and movement of each of the one or more
brace mechanisms to its retracted configuration positions its
corresponding formwork component at a location that is further from
the interior bore wall.
24. A system according to claim 20 wherein the bracing station is
configured to engage the one of the lining segments when its brace
mechanisms are in their extended configurations by deforming at
least a portion the one of the lining segments, such that resilient
deformation forces tend to couple the one of the lining segments to
the bracing station.
25. A system according to claim 20 wherein the bracing station is
configured to engage the one of the lining segments when its brace
mechanisms are in their extended configurations by exerting
pressure from the one or more formwork components on the one of the
lining segments to thereby form a pressure fit between the formwork
components and the one of the lining segments.
26. A system according to claim 20 comprising one or more anchors
which are coupleable to the one of the lining segments and which
extend from the one of the lining segments toward the interior bore
wall, the one or more anchors comprising one or more corresponding
anchoring components at locations spaced apart from the one of the
lining segments such that concrete at least partially encases the
one or more anchoring components when the concrete cures.
27. A system according to claim 20 comprising a working platform
which is coupleable to the bracing station to support workers,
thereby allowing the workers to perform work in the bore.
28. A system according to claim 27 comprising a platform axial
movement mechanism for moving the working platform independently of
the bracing station.
29. A reinforcement structure for reinforcing covering and
reinforcing at least a portion of an interior wall of a bore, the
reinforcement structure comprising: a plurality of axially abutting
reinforcement structure segments fabricated from concrete, each of
the reinforcement structure segments covering a corresponding
portion of the interior bore wall; a lining comprising a plurality
of axially abutting lining segments fabricated from a
non-cementitious material, each of the lining segments shaped to
provide at least a portion of an interior surface of a
corresponding reinforcement structure segment; a plurality of
anchors which are coupled to the lining segments and which extend
from the lining segments toward the interior bore wall for
anchoring the lining segments to the reinforcement structure
segments; wherein transitions between axially abutting lining
segments are offset from transitions between axially abutting
reinforcement structure segments.
30. A reinforcement structure according to claim 29 wherein the
transitions between axially abutting lining segments are offset
from the transitions between axially abutting reinforcement
structure segments by a length that is greater than 5% of the axial
dimension of the lining segments.
31. A reinforcement structure according to claim 29 wherein a first
subset of the plurality of anchors extends axially across a
transition between a first one of the plurality of reinforcement
structure segments and an axially adjacent second one of the
plurality of reinforcement structure segments and anchors one or
more of the plurality of lining structure segments to the first and
second reinforcement structure segments
32. A reinforcement structure according to claim 29 wherein a first
subset of the plurality of anchors extends axially across a
transition between a first one of the plurality of lining segments
and an axially adjacent second one of the plurality of lining
segments and is coupled to both the first and second lining
segments.
33. A reinforcement structure according to claim 29 comprising a
rebar lattice that extends axially across a transition between a
first one of the plurality of reinforcement structure segments and
an axially adjacent second one of the plurality of reinforcement
structure segments.
34. A reinforcement structure according to claim 29 wherein the
concrete used to fabricate each of the reinforcement structure
segments cures at different times.
Description
RELATED APPLICATIONS
[0001] This application claims priority from U.S. application No.
61/384,703 entitled SYSTEMS AND METHODS FOR PROVIDING A
CONCRETE-REINFORCED BORE and Canadian application No. 2,714,763
entitled SYSTEMS AND METHODS FOR PROVIDING A CONCRETE-REINFORCED
BORE, both of which were filed on 20 Sep. 2010 and both of which
are hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention pertains to construction of bores. Particular
embodiments, provide systems and methods for providing a concrete
reinforced bore.
BACKGROUND
[0003] There are many wide varying reasons to provide bores in the
ground. By way of non-limiting example, such bores can be used for
fluid conduits (e.g. gas pipelines, aqueducts, sewers and/or the
like), accesses to underground regions (e.g. manhole shafts, mine
shafts, water wells and/or the like), receiving anchors or other
supports for above-grade structures (e.g. anchors for bridges,
buildings, towers, road infrastructure and/or the like),
geotechnical investigations and/or other applications.
[0004] In some instances, there is a desire to reinforce such a
bore with concrete or other similar curable construction material
or to otherwise cover the interior surface of a bore (or a portion
thereof) with concrete or similar curable construction material. In
some applications, it can be desirable that such concrete
reinforcement and/or covering provide structural integrity to the
bore and/or to the interior surface thereof. In some applications,
there may be a desire to line such concrete reinforcement and/or
covering with a lining that has properties different from that of
concrete.
SUMMARY OF THE INVENTION
[0005] One aspect of the invention provides a system for
reinforcing a bore using concrete to provide a lined reinforcement
structure that covers at least a portion of an interior wall of the
bore. The system comprises: a lining comprising a plurality of
axial lining segments, each lining segment shaped to provide at
least a portion of an interior surface of a corresponding axially
extending reinforcement structure segment that covers at least a
portion of the interior bore wall; one or more anchors which are
coupled to or integrally formed with the lining segment and extend
toward the interior bore wall to couple the lining segment to the
corresponding reinforcement structure segment; a bracing station
shaped for axial movement along the bore, the bracing station
comprising one or more formwork components and one or more
corresponding brace mechanisms for bracing the formwork components
against forces directed inwardly from the interior bore wall. Each
of the one or more brace mechanisms is moveable between a retracted
configuration and an extended configuration, wherein its
corresponding formwork component is closer to the interior bore
wall when in the extended configuration as compared to when in the
retracted configuration. The system also comprises an axial
movement mechanism operatively coupled to the bracing station for
moving the bracing station axially along the bore. The bracing
station is configured to engage one of the axial lining segments
when its brace mechanisms are in their extended configurations such
that the axial lining segment moves axially along the bore with the
bracing station and to release, and to move independently of, the
axial lining segments when its brace mechanisms are in their
retracted configurations.
[0006] Each lining segment may be engaged by the bracing station by
moving the brace mechanisms to their extended configurations and
then the bracing station and lining segment can be moved together
axially along the bore to a desired axial location by the axial
movement mechanism. A corresponding reinforcement structure segment
may then be fabricated by introducing concrete into a space between
the interior bore wall and the lining segment. The formwork
components of the bracing station may provide at least a portion of
the formwork to enclose the liquid concrete and the brace
mechanisms of the bracing station may be used to brace the formwork
components against the pressure of the liquid concrete until the
concrete of the reinforcement structure segment cures. Once a
particular reinforcement structure segment is fabricated (i.e. the
concrete cures), the brace mechanisms may be moved to their
retracted configurations to decouple the bracing station from the
lining segment and the axial movement mechanism can move the
bracing station axially along the bore and to a location where the
bracing station can engage another lining segment and repeat the
process until the reinforcement structure is fabricated. Once the
reinforcement structure is fabricated, the brace mechanism and the
axial movement mechanism may be removed from the bore.
[0007] In some embodiments, when the brace mechanisms are in their
extended configurations the bracing station is sized to engage the
lining segment by deforming at least a portion the lining segment,
such that resilient deformation forces (i.e. forces that tend to
elastically restore the shape of the lining segment) tend to couple
the lining segment to the bracing station. In some embodiments,
when the brace mechanisms are in their extended configurations the
bracing station exerts pressure on the lining segment and thereby
forms a friction (pressure) fit between the formwork components and
the lining segment.
[0008] In some embodiments, the transitions between adjacent
reinforcement structure segments may be axially offset from
transitions between adjacent lining segments. In some embodiments,
this axial offset may be greater than 5% of the axial dimension of
the lining segments. In some embodiments, this axial offset may be
greater than 10% of the axial dimension of the lining segments. In
some embodiments, anchors coupled to lining segments may extend
axially between two ore more axially adjacent reinforcement
structure segments and/or between two or more axially adjacent
lining segments. In some embodiments, the axial extension of
anchors beyond a trailing edge of a particular lining segment may
comprise a variety of different extension lengths.
[0009] In some embodiments, the bracing station comprises one or
more brace mechanism actuators for moving the brace mechanisms
between their retracted configurations and their extended
configurations. In some embodiments the bracing station can
comprise one or more working platforms which provide support for
workers and allow the workers to perform work in the bore. In some
embodiments, the system comprises a working platform and an axial
movement mechanism that permits axial movement of the working
platform along the bore independently of the bracing station. Work
performed by workers supported on the working platform may comprise
cleaning, grinding, removing debris from or otherwise preparing the
interior bore wall to accept concrete, assembling reinforcement bar
(rebar) lattices which will be encased in the concrete of the
reinforcement structure and/or the like. In some embodiments, the
rebar lattices can extend axially between two or more axially
adjacent reinforcement structure segments and/or between two or
more adjacent lining segments.
[0010] In some embodiments, the system provides a secondary
reinforcement structure which is constructed inside a bore defined
by the first reinforcement structure. The secondary reinforcement
structure may be assembled in a manner similar to the first
reinforcement structure except that an interior surface of the
lining of the first reinforcement structure takes the place of the
interior bore wall and the secondary reinforcement structure covers
at least a portion of the interior surface of the lining of the
first reinforcement structure. The lining of the first
reinforcement structure may be fabricated from a material to which
the concrete of the secondary reinforcement structure does not
bond, thereby permitting relative slidable movement between the
secondary reinforcement structure and the interior surface of the
lining of the first reinforcement structure under seismic activity
and/or the like. The interior surface of the lining of the first
reinforcement structure may be sufficiently smooth to permit
relative slidable movement between the secondary reinforcement
structure and the interior surface of the lining of the first
reinforcement structure under seismic activity and/or the like.
[0011] Systems for providing reinforcement structures may use other
curable materials in addition to or in the alternative to
concrete.
[0012] Another aspect of the invention provides a method for
providing a lined reinforcement structure that covers at least a
portion of an interior wall of a bore, the method comprises:
providing a lining comprising a plurality of axial lining segments,
each lining segment providing an interior surface of at least a
portion of a corresponding axially extending reinforcement
structure segment that covers at least a portion of the interior
bore wall, each lining segment coupleable to the corresponding
reinforcement structure segment; providing a bracing station
axially moveable along the bore, the bracing station comprising one
or more formwork components and one or more corresponding brace
mechanisms for bracing the formwork components against forces
directed inwardly from the interior bore wall. Each of the one or
more brace mechanisms is moveable between a retracted configuration
and an extended configuration, wherein its corresponding formwork
component is closer to the interior bore wall when in the extended
configuration as compared to when in the retracted
configuration.
[0013] Methods according to particular embodiments may involve:
moving the brace mechanisms to their extended configurations to
thereby cause the bracing station to engage one of the lining
segments such that the lining segment moves axially along the bore
with the bracing station; moving the bracing station and the lining
segment axially along the bore to a desired axial location;
fabricating a reinforcement structure segment by introducing
concrete into at least a portion of a space between the interior
bore wall and the lining segment; counteracting at least some of
the forces created by the pressure of the liquid concrete using the
formwork components and the bracing components of the bracing
platform until the concrete of the reinforcement structure segment
cures in the space between interior bore wall and the lining
segment; after the concrete cures, moving the brace mechanisms to
their retracted configurations to decouple the bracing station from
the lining segment; moving the bracing station axially along the
bore and to a location where the bracing station can engage another
lining segment; and repeating the process until the reinforcement
structure is fabricated.
[0014] In some embodiments, moving the brace mechanisms to their
extended configurations to thereby cause the bracing station to
engage one of the axial lining segments may comprise deforming at
least a portion the lining segment, such that resilient deformation
forces (i.e. forces that tend to elastically restore the shape of
the lining segment) tend to couple the lining segment to the
bracing station. In some embodiments, moving the brace mechanisms
to their extended configurations causes the bracing station to
exert pressure on the lining segment and thereby forms a friction
(pressure) fit between the formwork components and the lining
segment.
[0015] In some embodiments, the method comprises axially offsetting
the transitions between adjacent reinforcement structure segments
from transitions between adjacent lining segments. In some
embodiments, this axial offset may be greater than 5% of the axial
dimension of the lining segments. In some embodiments, this axial
offset may be greater than 10% of the axial dimension of the lining
segments. In some embodiments, the method comprises coupling
anchors to lining segments such that the anchors extend axially
between two ore more axially adjacent reinforcement structure
segments and/or between two or more axially adjacent lining
segments. In some embodiments, the axial extension of anchors
beyond a trailing edge of a particular lining segment may comprise
a variety of different extension lengths.
[0016] In some embodiments, the method comprises providing a
working platform which is supported by or coupled to the bracing
station and which provides support for workers, thereby allowing
the workers to perform work in the bore. In some embodiments, the
method comprises moving the working platform axially along the bore
independently of the bracing station. In some embodiments, the
method comprises assembling reinforcement bar (rebar) lattices
which will be encased in the concrete of the reinforcement
structure. In some embodiments, such rebar lattices may extend
axially between two or more axially adjacent reinforcement
structure segments and/or lining segments.
[0017] In some embodiments, the method comprises fabricating a
secondary reinforcement structure inside a bore defined by the
first reinforcement structure. The secondary reinforcement
structure may be fabricated in a manner similar to the first
reinforcement structure except that an interior surface of the
lining of the first reinforcement structure takes the place of the
interior bore wall and the secondary reinforcement structure covers
at least a portion of the interior surface of the lining of the
first reinforcement structure. The lining of the first
reinforcement structure may be fabricated from a material to which
the concrete of the secondary reinforcement structure does not
bond, thereby permitting relative slidable movement between the
secondary reinforcement structure and the interior surface of the
lining of the first reinforcement structure under seismic activity
and/or the like. The interior surface of the lining of the first
reinforcement structure may be sufficiently smooth to permit
relative slidable movement between the secondary reinforcement
structure and the interior surface of the lining of the first
reinforcement structure under seismic activity and/or the like.
[0018] Methods for providing reinforcement structures may use other
curable materials in addition to or in the alternative to
concrete.
[0019] Another aspect of the invention provides a method for
providing a lined reinforcement structure that covers at least a
portion of an interior wall of a bore. The method involves: (a)
providing a plurality of axial lining segments; (b) providing a
bracing station axially moveable along the bore, the bracing
station comprising one or more formwork components coupled to one
or more brace mechanisms for bracing the formwork components
against forces directed inwardly from the interior bore wall, the
one or more brace mechanisms moveable between extended
configurations wherein the formwork components are closer to the
interior bore wall and retracted configurations wherein the
formwork components are further from the interior bore wall; (c)
engaging one of the lining segments with the bracing station such
that the one of the lining segments moves axially along the bore
with the bracing station; (d) moving the bracing station and the
one of the lining segments axially along the bore to a desired
axial location; (e) fabricating a reinforcement structure segment
by introducing liquid concrete into at least a portion of a space
between the interior bore wall and the one of the lining segments;
(f) anchoring the one of the lining segments to the reinforcement
structure segment; (g) after the concrete cures, decoupling the
bracing station from the one of the lining segments such that the
bracing station is axially moveable within the bore independently
of the one of the lining segments; and (h) repeating steps (c)
through (g) until the reinforcement structure is fabricated.
[0020] Another aspect of the invention provides a system for
providing a lined reinforcement structure that covers at least a
portion of an interior wall of a bore. The system comprises: a
plurality of axial lining segments; a bracing station shaped for
axial movement along the bore, the bracing station comprising one
or more formwork components coupled to one or more brace mechanisms
for bracing the formwork components against forces directed
inwardly from the interior bore wall, the one or more brace
mechanisms moveable between extended configurations wherein the
formwork components are closer to the interior bore wall and
retracted configurations wherein the formwork components are
further from the interior bore wall, wherein bracing station is
configured to engage one of the axial lining segments when its
brace mechanisms are in their extended configurations such that the
one of the axial lining segments moves axially along the bore with
the bracing station and to release, and to move independently of,
the one of the axial lining segments when its brace mechanisms are
in their retracted configurations; and an axial movement mechanism
to move the bracing station axial within the bore.
[0021] Another aspect of the invention provides a reinforcement
structure for reinforcing covering and reinforcing at least a
portion of an interior wall of a bore. The reinforcement structure
comprises: a plurality of axially abutting reinforcement structure
segments fabricated from concrete, each of the reinforcement
structure segments covering a corresponding portion of the interior
bore wall; a lining comprising a plurality of axially abutting
lining segments, each of the lining segments shaped to provide at
least a portion of an interior surface of a corresponding
reinforcement structure segment; and a plurality of anchors which
are coupled to the lining segments and which extend from the lining
segments toward the interior bore wall for anchoring the lining
segments to the reinforcement structure segments. Transitions
between axially abutting lining segments are offset from
transitions between axially abutting reinforcement structure
segments.
[0022] The transitions between axially abutting lining segments may
be offset from the transitions between axially abutting
reinforcement structure segments by a length that is greater than
5% of the axial dimension of the lining segments. In some
embodiments, this offset is greater than 10% of the axial dimension
of the lining segments.
[0023] A first subset of the plurality of anchors may extend
axially across a transition between a first one of the plurality of
reinforcement structure segments and an axially adjacent second one
of the plurality of reinforcement structure segments and may anchor
one or more of the plurality of lining structure segments to the
first and second reinforcement structure segments. A first subset
of the plurality of anchors may extend axially across a transition
between a first one of the plurality of lining segments and an
axially adjacent second one of the plurality of lining segments and
may be coupled to both the first and second lining segments.
[0024] The reinforcement structure may comprise a rebar lattice
that extends axially across a transition between a first one of the
plurality of reinforcement structure segments and an axially
adjacent second one of the plurality of reinforcement structure
segments.
[0025] The concrete used to fabricate each of the reinforcement
structure segments may be allowed to cure at different times.
[0026] Other aspects and features of various embodiments will
become apparent from the following description and claims and from
the accompanying drawings which form part of this
specification.
BRIEF DESCRIPTION OF DRAWINGS
[0027] In drawings which illustrate non-limiting embodiments of the
invention:
[0028] FIG. 1A and FIG. 1B (together, FIG. 1) are respectively
cut-away isometric and top plan views of an exemplary bore which
may be reinforced using systems and methods according to particular
embodiments of the invention;
[0029] FIG. 2A is a top plan view of the FIG. 1 bore after being
reinforced using a lined concrete reinforcement structure in
accordance with particular embodiments of the invention;
[0030] FIG. 2B is a top plan view of the FIG. 1 bore after being
reinforced using a lined concrete reinforcement structure in
accordance with other embodiments of the invention;
[0031] FIG. 3A is an isometric view of a lining segment which may
be used to line a concrete reinforcement structure according to an
example embodiment;
[0032] FIG. 3B is a magnified, partial top elevation view of a
number of panels and anchors of the FIG. 3A lining segment;
[0033] FIGS. 4A and 4B (together, FIG. 4) are schematic top
elevation views of a bracing station which may be used to reinforce
a bore with concrete according to a particular embodiment of the
invention in an outwardly extended configuration and a partially
retracted configuration respectively;
[0034] FIG. 5 is a schematic isometric view of the FIG. 4 bracing
station;
[0035] FIGS. 6A-6F are cut-away isometric views showing the use of
the FIG. 4 bracing station and a plurality of the FIG. 3A and FIG.
3B lining segments to construct the FIG. 2B reinforcement
structure; and
[0036] FIG. 7 is a top plan view of the FIG. 1 bore after being
reinforced using a two-part lined concrete reinforcement structure
in accordance with particular embodiments of the invention.
DESCRIPTION
[0037] Throughout the following description, specific details are
set forth in order to provide a more thorough understanding of the
invention. However, the invention may be practiced without these
particulars. In other instances, well known elements have not been
shown or described in detail to avoid unnecessarily obscuring the
invention. Accordingly, the specification and drawings are to be
regarded in an illustrative, rather than a restrictive, sense.
[0038] Particular embodiments provide systems and methods for
reinforcing a bore using concrete to provide a lined reinforcement
structure that covers at least a portion of an interior wall of the
bore. The reinforcement structure is lined with a plurality of
axially adjacent lining segments. Each lining segment may be
provided with anchors for projecting into the liquid concrete such
that they are at least partially encased in concrete as the
concrete cures. Each lining segment is carried to its axial
position by a bracing station capable of axial movement within the
bore. The bracing station is capable of increasing its
cross-section to an extended configuration where it can engage a
lining segment and decreasing its cross-section to a retracted
configuration where it can move in the bore independently of the
lining segment. After a lining segment is moved into place by the
bracing station, concrete may be introduced into at least a portion
of a space between the lining segment and an interior wall of the
bore to form segment of the reinforcement structure. The bracing
station provides formwork and bracing to counteract the force of
the liquid concrete until it cures to provide the reinforcement
structure segment. The process may be repeated to provide a
plurality of adjacent lining segments and reinforcement structure
segments which together may form the reinforcement structure.
[0039] Bore-reinforcing structures in accordance with particular
aspects of the invention may be fabricated in part from concrete or
other curable construction materials. For brevity, this description
and the accompanying claims refer to such reinforcement structures
as being fabricated in part from concrete. Unless otherwise
specified, however, references to concrete in this description and
the accompanying claims should be understood to include other
suitable curable construction materials.
[0040] FIGS. 1A and 1B are respectively cut-away isometric and top
plan views of an exemplary bore 10 which may be reinforced using
systems and methods according to particular embodiments of the
invention to provide a lined reinforcement structure that covers at
least a portion of an interior wall 12 of bore 10. Exemplary bore
10 happens to be fabricated in the earth 16 and happens to be
vertically oriented, although embodiments of the invention may be
employed in bores fabricated in other materials and/or having other
orientations. Bore 10 comprises an interior bore wall 12 which
defines an elongated bore hole 14. In the illustrated embodiment,
interior bore wall 12 is shaped such that bore hole 14 is generally
circular in cross-section. Again, however, this is not necessary
and embodiments of the invention could be used in bores having
other cross-sections.
[0041] There are many wide varying reasons to provide bores (like
bore 10). By way of non-limiting example, such bores can be used
for fluid conduits (e.g. gas pipelines, aqueducts, sewers and/or
the like), accesses to underground regions (e.g. manhole shafts,
mine shafts, water wells and/or the like), receiving anchors or
other supports for above grade structures (e.g. anchors for
bridges, buildings, towers, road infrastructure and/or the like),
geotechnical investigations and/or other applications.
[0042] It is often desirable to reinforce bores, particularly bores
formed in the earth or in other non-homogeneous or non-stable
materials. Such reinforcement can prevent or minimize the amount of
material from interior bore wall 12 or from the surrounding
material (e.g. earth 16) which collapses into bore hole 14.
Particular embodiments provide systems and methods for reinforcing
a bore (e.g. bore 10) using concrete to provide a lined
reinforcement structure that covers at least a portion of interior
bore wall 12.
[0043] In one particular application, bore 10 may be formed as
follows: a cutting tool may be used to cut a generally
annular-shaped cylinder in the ground; the annular cylinder may be
filled with a temporary filler material (e.g. bentonite clay or the
like) at about the same time as earth is removed from the annular
cylinder. Then, concrete may be pumped to the bottom of the annular
cylinder, forcing the temporary filler material out the top of the
annular cylinder. The concrete pumped into the annular cylinder
cures between the earth that forms the inside and outside surfaces
of the annular cylinder to provide an annular cylinder of
solidified concrete 18 (FIG. 1B). The earth inside concrete annular
cylinder 18 may then be excavated or otherwise removed using any
suitable means. This excavation creates bore hole 14. Bore hole 14
is defined by an interior bore wall 12 which is the interior
surface of concrete annular cylinder 18. Where annular cylinder 18
originally cut into earth 16 has a generally round cross-section
(as is the case in the illustrated FIG. 1 bore 10), bore hole 14
may also have a generally round cross-section. However, because of
the non-homogeneous nature of earth 16 in which bore 10 is formed,
generally annular cylinder 18 and interior bore wall 12 fabricated
in this manner may be uneven, rough and may have significant
amounts of earth, rock and/or other material embedded therein or
otherwise stuck thereto. In addition to reinforcing bore 10, in
some applications, it might be desirable to provide a bore-hole
defining surface that is relatively smooth and/or uncontaminated in
comparison to interior bore wall 12.
[0044] The preceding description represents one particular
non-limiting technique for creating a bore 10 defined by an
interior bore wall 12 and having a bore hole 14. Generally
speaking, however, bores like bore 10 may be created by any other
suitable technique which is known or which may become known in the
art and embodiments of the invention described herein should be
understood to have application to any such bores. For the purposes
of explanation, the description that follows will refer to bore 10
of FIG. 1, without loss of generality.
[0045] Particular aspects of the invention provide methods and
systems for reinforcing bore 10 using concrete to provide a lined
reinforcement structure that covers at least a portion of interior
bore wall 12. FIG. 2A is a top plan view of bore 10 after being
reinforced using a lined concrete reinforcement structure 20 in
accordance with a particular embodiment of the invention.
Reinforcement structure 20 comprises concrete 22 that covers at
least a portion of interior bore wall 12 and is lined on its
interior surface 24 with a liner 26. Interior surface 24 of
reinforcement structure 20 (as provided by liner 26) defines a
reinforced bore hole 14A of a reinforced bore 10A. Interior surface
24 of reinforcement structure 20 (as provided by liner 26) may
provide a relatively smooth bore-defining surface 24 as compared to
interior bore wall 12. In the illustrated embodiment, reinforcement
structure 20 also comprises a lattice 28 of suitably placed
reinforcement bar (commonly referred to as rebar) 30 which provides
additional strength and structural integrity to reinforcement
structure 20.
[0046] FIG. 2B is a top plan view of bore 10 after being reinforced
using a lined concrete reinforcement structure 20' in accordance
with another particular embodiment of the invention. Reinforcement
structure 20' is substantially similar to reinforcement structure
20 of FIG. 2A, except that reinforcement structure 20' does not
include lattice 28 of rebar 30. In the following description,
reinforcement structures are referred to using reference numeral
20, it being understood that unless specified otherwise, such
reinforcement structures 20 could be constructed with or without
lattice 28 of rebar 30.
[0047] Liner 26 of reinforcement structure 20 may be fabricated
from a non-cementitious material. Liner 26 may be elastically
deformable, at least relative to concrete 22 of reinforcement
structure 20. Liner 26 may be impermeable to water or other liquids
at the temperatures and pressures under which bore 10 is being
considered for use. Suitable materials from which liner 26 may be
fabricated include without limitation: plastics (e.g. polyvinyl
chloride (PVC), acrylonitrile butadiene styrene (ABS) or the like),
suitable metal alloys, suitable ceramics, suitable fiberglass
materials. suitable carbon fiber materials and/or the like. In the
illustrated embodiment, liner 26 is a modular liner comprising a
plurality of interconnected panels 26A which are coupled to one
another to provide the cross-sectional shape desired for reinforced
bore hole 14A. In the illustrated embodiment, the cross-sectional
shape desired for reinforced bore hole 14A is generally
circular.
[0048] As explained in more detail below, lining 26 may comprise a
plurality of axially adjacent lining segments 32, each of which has
an axial dimension that extends along a corresponding portion of
the axial dimension of bore 10. Only one such lining segment 32 is
visible in the illustrated views of FIG. 2A and FIG. 2B.
[0049] FIG. 3A is an isometric view of a lining segment 32 which
may be used to line an axial portion of concrete reinforcement
structure 20 according to an example embodiment. Lining segment 32
of the illustrated embodiment is modular and comprises a plurality
of interconnected panels 26A which are coupled to one another to
provide a generally circular cross-sectional shape for reinforced
bore hole 14A. It will be appreciated that lining segments similar
to lining segment 32 could be provided with other cross-sections to
provide reinforced bore hole 14A having other cross-sectional
shapes.
[0050] Lining segment 32 has an axial dimension 36 defined between
a pair of edges 38A, 38B. Edge 38A may be referred to as trailing
edge 38A and edge 38B may be referred to as leading edge 38B While
axial dimension 36 may generally be any length, typical axial
dimensions 36 of lining segments 32 may be in a range of 2-20 feet
(e.g. 4 feet, 8 feet, 12 feet and/or 16 feet), which may represent
a compromise between ease of transport and ease of construction.
Smaller axial dimensions 36 may be achieved by cutting panels 26A
to length. As discussed above, axial dimension 36 of lining segment
32 may represent a fraction of the axial dimension of bore 10 and a
plurality of lining segments 32 may be located axially adjacent to
one another (i.e. with trailing edge 38A of one lining segment 32
abutting or at least in close proximity to leading edge 38B of an
axially adjacent lining segment 32).
[0051] FIG. 3B is a magnified, partial top elevation view of a
number of panels 26A and anchors 34 of the FIG. 3A lining segment
32. Panels 26A have an elongated dimension which is into and out of
the page in the FIG. 3B view. The elongated dimensions of panels
26A may be oriented along the axis of bore 10 and may define the
axial length 36 of lining segment 32.
[0052] Panels 26A comprise complementary connector components 40A,
40B at their respective edges 41A, 41B. Complementary connector
components 40A, 40B may be coupled to one another to provide
connections 42 between edges 41A, 41B of adjacent panels 26A to
thereby couple panels 26A to one another in an edge-adjacent
relationship. Connector components 40A, 40B of the illustrated
embodiment may be similar to those described in PCT application No.
PCT/CA2008/001951 (published under WO2009/059410) and PCT
application No. PCT/CA2008/000608 (published under WO2008/119178)
which are hereby incorporated herein by reference. More
particularly, connector components 40A, 40B of the illustrated
embodiment may be coupled to one another by effecting relative
pivotal movement between edge-adjacent panels 26A and/or between
connector components 40A, 40B. Such relative pivotal motion may
cause deformation of one or both of connector components 40A, 40B,
such that restorative deformation forces (i.e. the forces that tend
to restore the shape of deformed connector component(s) 40A, 40B)
act to lock connector components 40A, 40B to one another, thereby
forming connections 42 which lock edge-adjacent panels 26A to one
another.
[0053] In other embodiments, complementary connector components
40A, 40B may be different. For example, connector components 40A
may comprise generally male connector components and connector
components 40B may comprise generally female connector components
which fit together to provide connections 42 between edge-adjacent
panels 26A. In one exemplary embodiment, generally male connector
components 40A may slide into generally female connector components
40B in the axial direction (i.e. in one of the directions indicated
by double headed arrow 43 of FIG. 3A) to lock connector components
40A, 40B to one another and to thereby provide connections 42. By
way of non-limiting example, such connector components and slidable
coupling may be similar to those described in PCT application No.
PCT/CA2008/000608 (published under WO2008/119178)--see for example
FIGS. 4A, 4B and 4C thereof. In general, connections 42 could be
provided by any other suitable complementary connector components
40A, 40B.
[0054] As shown best in FIG. 3B, lining 26 may also comprise
anchors 34 which help to anchor lining 26 to concrete 22. In the
illustrated embodiment, anchors 34 extend outwardly from interior
surface 24 of reinforcement structure 20 toward interior bore wall
12 (i.e. into concrete 22)--see FIGS. 1 and 2. This outward
direction which anchors 34 extend from interior surface 24 is shown
by arrow 44 of FIG. 3B, but generally includes any direction
oriented from interior surface 24 toward interior bore wall 12.
Anchors 34 may comprise one or more anchoring features 46 at
locations outwardly spaced apart from interior surface 24 (e.g.
spaced apart from interior surface 24 in outward direction 44).
Concrete 22 may flow into the spaces between anchoring features 46
and surface 24 when concrete 22 is in liquid form and anchoring
features 46 may be encased (or at least partially encased) in
concrete 22 as concrete 22 cures to thereby anchor lining 26 to
concrete 22. Anchors 34 may be apertured (not shown) to facilitate
the flow of concrete 22 therethrough. For example, anchors 34 may
be apertured such that concrete can flow in the transverse
directions represented by double-headed arrow 48 of FIG. 3B.
[0055] Anchors 34 may also have an elongated dimension that is into
and out of the page in FIG. 3B. The elongated dimensions of anchors
34 panels 26A may be oriented along the axis of bore 10. In some
embodiments, the elongated dimension of anchors 34 may be the same
as the elongated dimension of panels 26A, although this is not
necessary. In some embodiments, the elongated dimension of panels
26A may be different than that of panels 26A. As explained in more
detail below, in some embodiments, the elongated dimensions of
anchors 34 may extend across one or both of edges 38A, 38B of a
particular lining segment 32 and may help to align and/or join the
particular lining segment 32 to an adjacent lining segment 32.
[0056] Anchoring features 46 of anchors 34 may extend in one or
more transverse directions (as represented by double-headed arrow
48 in FIG. 3B) and in one or more axial directions (as represented
by double-headed arrow 43 in FIG. 3A). In the illustrated
embodiment, anchoring features 46 comprise barb shaped anchoring
features 46A which are angularly oriented with respect to interior
surface 24 and flat anchoring features 46B which are oriented
parallel to surface 24. In general, anchors 34 and anchoring
features 46 may be provided with a wide variety of shapes.
Non-limiting examples of anchors and anchoring features that may be
used in various embodiments of the invention are described in PCT
application No. PCT/CA2008/000608 (published under
WO2008/119178).
[0057] In the illustrated embodiment, anchors 34 are provided as
separate components which are connected to panels 26A by the
interaction of complementary connector components 50 of panels 26A
and connector components 52 of anchors 34 which provide connections
54. In the illustrated embodiment, connector components 52 of
anchors 34 are male connector components which slide (in axial
directions 43) into complementary female connector components 50 of
panels 26A to provide connections 54. In other embodiments,
connector components 50 could be male connector components and
connector components 52 could be female connector components. In
still other embodiments, connections 54 could be provided by any
other suitable complementary connector components which may be
connected to one another by any suitable connection method,
including, for example, "snap together" connections involving
deformation of the connector components and connections formed by
restorative deformation forces.
[0058] In some embodiments, where the elongated dimensions of
anchors 34 extend across one or both of edges 38A, 3B of a
particular lining segment 32, the connector component 52 of anchors
34 may be coupled to connector components 50 (and thereby form
connections 54) with panels 26A from adjacent lining segments
32.
[0059] In some embodiments, the connector components 52 of anchors
34 may be used to connect panels 26A in edge-adjacent relationship
rather than panels 26A being connected directly to one another.
Anchors 34 used in this manner may be similar to the connector-type
anchoring components described in PCT application No.
PCT/CA2008/000608 (published under WO2008/119178). In still other
embodiments, anchors 34 may be integrally formed with panels
26A--i.e. anchors 34 need not be separate components from panels
26A. In the illustrated embodiment, one anchor 34 is connected to
each panel 26A. This is not necessary and the ratio of anchors 34
to panels 26A may be greater than or less than one.
[0060] In some embodiments, panels 26A may be provided with one or
more optional stiffening features 56 which, in addition to
stiffening panels 26A may provide some additional anchoring of
panels 26A into concrete 22. Panels 26A and anchors 34 may be
fabricated by extrusion, although this is not necessary.
Advantageously, panels 26A may be generally flat in their
non-stressed state, but may be resiliently deformed to provide the
arcuate shape shown in FIG. 3B. Providing panels 26A with a flat
shape can make it easier to store and/or transport panels 26A.
Similarly, providing panels 26A and anchors 34 as separate
components can make it easier to store and/or transport panels 26A
and anchors 34.
[0061] FIGS. 4A and 4B are schematic top elevation views of, and
FIG. 5 is a schematic isometric view of, a bracing station 100
which may be used to construct reinforcement structure 20 and to
thereby reinforce bore 10 according to a particular embodiment of
the invention. FIGS. 4A and 5 show bracing station 100 in an
outwardly extended configuration 102A and FIG. 4B shows bracing
station 100 a partially retracted configuration 102B. Bracing
station 100 comprises a plurality of formwork components 104 each
of which is operatively connected to (or integrally formed with) a
corresponding brace mechanism 106. In the illustrated embodiment,
bracing station 100 comprises eight formwork components 104A-104H
and eight corresponding brace mechanisms 106A-106H. Bracing station
100 may also comprise a structural framework 110 incorporating one
or more structural components 112. Structural framework 110
supports and provides structural reinforcement for brace mechanisms
106 and formwork components 104. Structural framework 110 may also
support one or more working platforms 114 on which men may work
inside bore 10.
[0062] As will be explained in more detail below, bracing station
100 is moveable axially along bore 10 (e.g. in bore hole 14). Each
brace mechanism 106 is configurable into an extended configuration
wherein brace mechanism 106 is elongated to position its
corresponding formwork component 104 at a location that is
relatively close to interior bore wall 12. When all of brace
mechanisms 106 are in their extended configurations, bracing
station 100 may be said to be in its extended configuration. FIGS.
4A and 5 show one particular embodiment of a bracing station 100 in
its extended configuration. Each bracing mechanism 106 is also
configurable into a retracted configuration wherein bracing
mechanism 106 is retracted to position its corresponding framework
component 104 at a location that is relatively far from interior
bore wall 12. FIG. 4B shows a particular embodiment of a bracing
station 100 wherein bracing mechanisms 106A, 106C, 106E, 106G have
been retracted toward their retracted configurations.
[0063] Bracing station 100 may also comprise one or more optional
actuators 108 for moving bracing mechanisms 106 between their
extended configurations and their retracted configurations. In the
illustrated embodiment, bracing station 100 comprises one actuator
108A-108H corresponding to each bracing mechanism 106, although
this is not necessary and in some embodiments, actuators 108 may be
operable to configure multiple bracing mechanisms 106. Suitable
actuators include, without limitation, electrical motors, hydraulic
actuators, hand powered actuators and/or the like. Actuators 108
may be separately controllable or collectively controllable by a
suitable controller (not shown) having a user input (e.g. a switch,
a joystick, a slider input and/or the like). Actuators 108 are not
strictly required. In some embodiments, bracing mechanisms 106 may
be manually adjusted between their extended configurations and
their retracted configurations by a user. By way of non-limiting
example, bracing mechanisms 106 may be adjusted between their
extended and retracted configurations by sliding one or more arms
of bracing mechanisms 106 into one or more other arms of bracing
mechanisms 106 and by locking bracing mechanisms with a suitable
locking device (e.g. a dowel pin, a ratchet locking pawl and/or the
like).
[0064] In some embodiments, when bracing mechanisms 106 are in
their extended configurations, the edges of adjacent formwork
components 104 may be close to and/or may touch one another. For
example, referring to FIG. 4A, the edges of formwork component 104A
may be close to and/or touch one edge of formwork component 104B
and one edge of formwork component 104H. In some embodiments, this
extended configuration proximity of the edges of adjacent formwork
components 104 may be less than the transverse width of panels 26A
(i.e. the width of panels 26A in direction 48 of FIG. 3B). As will
be explained in more detail below, this extended configuration
proximity is advantageous for bracing lining segments 32 and to
ensure that panels 26A of lining segments 32 do not decouple from
one another under the weight of liquid concrete.
[0065] This extended configuration proximity of the edges of
adjacent formwork components 104 may require that bracing
mechanisms 106 be retracted toward their retracted configurations
at different times to avoid interaction between formwork components
104. This is shown in the illustrated embodiment of FIG. 4B, where
bracing mechanisms 106A, 106C, 106E, 106G are retracted. As can be
seen from FIG. 4B, when bracing mechanisms 106B, 106D, 106F, 106H
are retracted, the edges of adjacent formwork components 104 will
overlap one another.
[0066] In some embodiments, working platform 114 is optionally also
configurable between a retracted configuration and an extended
configuration. In FIGS. 4A and 4B, working platform 114 is shown in
its retracted configuration. It can be seen that in the retracted
configuration, working platform 114 is spaced apart from formwork
components 104. When working platform 114 is adjusted into its
extended configuration, it extends relatively closer to formwork
components 104--i.e. into region 116 shown in FIG. 4A.
[0067] Bracing station 100 may be moved axially within bore 10
(i.e. within bore hole 14) by an axial movement mechanism. For
clarity and because the axial movement mechanism will be understood
to those skilled in the art in view of this disclosure, the axial
movement mechanism is not expressly shown. The axial movement
mechanism may generally comprise any movement mechanism capable of
moving bracing station axially within bore 10. By way of
non-limiting example, where bore 10 is vertically oriented as is
the case in the illustrated embodiment, the axial movement
mechanism may comprise: a crane that may be coupled to bracing
station 100 (e.g. to framework 110) which may raise and lower
bracing station 100 within bore 10; an elevator-type movement
mechanism that is coupled to bracing station 100 (e.g. to framework
110) which may raise and lower bracing station 100 within bore 10,
a hydraulic piston movement mechanism which may raise or lower
bracing station 100 within bore 10 and/or the like. It will be
appreciated by those skilled in the art that where bore 10 has
other orientations, different axial movement mechanisms may be used
to move bracing station 100 axially along bore 10.
[0068] FIGS. 6A-6F show the use of bracing station 100 and a
plurality of lining segments 32 to reinforce bore 10 using concrete
according to an example embodiment and to thereby construct
reinforcement structure 20' that covers at least a portion of
interior bore wall 12. Prior to building anything inside bore hole
14, workers may clean, grind, remove debris from or otherwise
prepare interior bore wall 12 to accept concrete. Such surface
preparation may involve removing material which may be stuck to
interior bore wall 12 (e.g. organic material, rocks and/or dirt).
Such surface preparation may improve the bonding between interior
wall bore 12 and concrete 22 of reinforcement structure 20'.
[0069] In the illustrated embodiment of FIGS. 6A-6F, the
reinforcement structure being constructed is a reinforcement
structure 20' similar to that of FIG. 2B which does not make use of
rebar reinforcement. However, in general, reinforcement structures
20 assembled using the technique of FIGS. 6A-6F may include rebar
30 as described above and as shown in FIG. 2A. The addition of
rebar 30 to reinforcement structures 20 is discussed in more detail
below.
[0070] Constructing reinforcement structure 20' involves assembling
a plurality of lining segments 32. Advantageously, lining segments
32 may be assembled outside of bore 10. As discussed above, lining
segments 32 may be assembled by making connections 42 to couple
edges 41A, 41B of panels 26A to one another in edge-adjacent
relationship. In some embodiments, anchors 34 may be coupled to
panels 26A of lining segments 32 outside of bore 10.
[0071] FIG. 6A shows how a first lining segment 32 is engaged by
bracing platform 100. This FIG. 6A engagement is effected by first
locating lining segment 32 in an accessible place where it can be
engaged by bracing platform 100. In some embodiments (e.g. where
the axial movement mechanism is provided by a crane or where a
crane or other suitable lifting mechanism is available), locating
lining segment 32 in an accessible place may mean locating lining
segment 32 adjacent to bore 10. In other embodiments (e.g. where it
is move difficult to move bracing platform 100 other than axially
along bore 10), then locating lining segment 32 in an accessible
place may mean locating lining segment 32 just at the edge of bore
10 (e.g just inside the bore or just outside the bore).
[0072] Before engaging first lining segment 32, bracing station 100
is adjusted to its retracted configuration by adjusting bracing
mechanisms 106 to their respective retracted positions. Then, with
bracing station 100 in its retracted configuration, bracing station
100 is moved adjacent to lining segment 32, where it can engage
lining segment 32. In the illustrated embodiment, bracing station
100 is moved into region 33 defined by interior surface 24 of
lining segment 32 (see FIG. 3A). As shown in FIG. 6A, brace
mechanisms 106 may then be moved to their extended configurations
to engage lining segment 32. Once engaged, lining segment 32 moves
with bracing station 100--e.g. axially within bore 10.
[0073] In the illustrated embodiment, when brace mechanisms 106 are
in their extended configurations, bracing station 100 is sized to
engage lining segment 32 by deforming at least a portion lining
segment 32 (e.g. bending, stretching or otherwise deforming panels
26A), such that resilient deformation forces (i.e. forces that tend
to elastically restore the shape of lining segment 32) tend to
couple lining segment 32 to formwork components 104 of bracing
station 100. In some embodiments, when brace mechanisms 106 are in
their extended configurations, bracing station 100 exerts pressure
on lining segment 32 and thereby forms a friction (pressure) fit
between formwork components 104 and lining segment 32. In other
embodiments, other mechanisms (e.g. mechanical arms, clamps, locks
or the like) may be used to engage bracing station 100 and lining
segment 32 when brace mechanisms 106 are in their extended
configurations. Such other mechanisms may engage edges 38A, 38B of
brace segment 32 in some embodiments and/or may penetrate through
brace segment 32 in some embodiments.
[0074] As can be seen from FIG. 6A, formwork components 104 may
have an axial dimension 122 (as defined by trailing edge 120A and
leading edge 120B) that is longer than axial dimension 36 of lining
segment 32. In the particular case of the illustrated embodiment,
this relative large axial dimension 122 of formwork components 104
causes formwork components 104 to extend beyond trailing edge 38A
of lining segment 32 in region 124. In some embodiments, a ratio of
the axial dimension 122 of formwork components 104 to the axial
dimension 36 of lining segment is greater than 1.05. In some
embodiments, this ratio is greater than 1.10. As will be discussed
in more detail below, the relatively large axial dimension 122 of
formwork components 104 can be used to provide an offset between
reinforcement structure segments 202 and lining segments 32 and can
help to brace edges 204A, 204B of adjacent reinforcement structure
segments 202 at the transitions 208 between adjacent reinforcement
structure segments 202 and edges 38A, 38B of adjacent lining
segments 32 at the transitions 60 between adjacent lining segments
32 when concrete is curing. This difference in axial dimensions
between formwork components 104 and lining segments 32 is not
necessary. In some embodiments, the axial dimension 122 of formwork
components 104 can be substantially similar to, or even less than,
the axial dimension 36 of lining segments 32.
[0075] Once bracing station 100 engages lining segment 32. the
axial movement mechanism moves the combination of bracing station
100 and lining segment 32 to a desired axial location for
installation of the first reinforcement structure segment 202. This
is shown in FIG. 6B, where bracing station 100 and lining segment
32 have been moved axially into a desired location in bore 10 by
the axial movement mechanism. Once bracing station 100 and lining
segment 32 are positioned roughly at a desired axial location, then
their axial positions may be finely adjusted (e.g. relative to bore
10 and/or to one another) by retracting one or more of bracing
mechanisms 106 slightly so that the friction/pressure fit between
formwork components 104 and lining segment 32 is relaxed enough to
effect relative movement between bracing station 100 and lining
segment 32.
[0076] In addition to fine axial adjustment, the position of lining
segment 32 and/or bracing station 100 may be adjusted in other
directions (e.g. transverse directions across bore 10). By way of
non-limiting example, in the illustrated embodiment, bracing
station 100 comprises one or more adjustable positioning elements
126 which may be used to align bracing station 100 and lining
segment 32 in one or more transverse direction across bore 10. Such
positioning elements 126 may be extended (e.g. by a threaded
adjustment mechanism, a ratcheting adjustment mechanisms and/or the
like) to push off of interior bore wall 12 at various locations and
to thereby adjust the position of bracing station 100 and lining
segment 32 within bore 10. In some embodiments (e.g. where lining
segment 32 has a round cross-section or does not cover an entire
axial swath of bore 10), lining segment 32 may be adjusted relative
to bracing station 100 by retracting one or more of bracing
mechanisms 106 slightly so that the friction/pressure fit between
formwork components 104 and lining segment 32 is relaxed enough to
effect relative movement between bracing station 100 and lining
segment 32. For example, in the illustrated embodiment, lining
segment 32 may be rotated around an exterior of bracing station 100
when the friction/pressure fit between formwork components 104 and
lining segment 32 is relaxed in this manner
[0077] In some embodiments, where a high degree of accuracy is
required for the placement of lining segment 32 and/or interior
surface 24 (FIG. 2), then laser alignment techniques may be used.
Such laser alignment techniques may involve, for example, providing
one or more laser targets (comprising photosensors or the like) at
one or more corresponding locations in bore 10. For example, in the
illustrated embodiment, such laser targets may be mounted at the
bottom of bore hole 14. For other bores, other suitable target
mounting locations may be used. Then, pipes, tubes or other
suitably apertured elements may be mounted on bracing station 100
at locations aligned axially with the laser targets and laser light
sources may be provided at the opposing end of bore 10 from the
laser targets at locations axially aligned with the laser targets.
Such laser light sources may be moveable into positions where they
do not extend over the opening of bore 10 (e.g. so that the laser
light sources do not interfere with the axial movement of bracing
station 100 to and/or through the opening of bore 10). With laser
light sources, laser targets and brace station apertures aligned in
this manner, then aligning a particular lining segment 32 becomes a
matter of moving bracing station 100 within bore 10, until the
laser light shines from the sources through the bracing station
apertures and strikes the laser targets.
[0078] To the extent that anchors 34 are not coupled to lining
segment 32 when lining segment 32 is moved into axial position
(FIG. 6B), then anchors 34 may be coupled to lining segment 32 at
this stage as described above. In some embodiments, it may be
desirable to provide anchors 34 that extend axially beyond trailing
edge 38A of lining segment 32. Such anchors 34 which extend beyond
trailing edge 38A may be used to help align lining segment 32 to an
adjacent lining segment 32 (as discussed in more detail below. In
some embodiments, some of the anchors 34 which extend beyond
trailing edge 38A may extend beyond trailing edge 38A by different
amounts--e.g. some anchors 34 may extend beyond trailing edge 38A
by 24 inches, some by 18 inches, some by 12 inches and some by 6
inches. This variation in extension of anchors 34 beyond trailing
edge 38A may be useful in aligning an adjacent lining segment 32 by
permitting a subset of the over-extending anchors 34 to be coupled
to the adjacent lining segment 32 at any given time.
[0079] Liquid concrete is then introduced into the space between
lining segment 32 and interior bore wall 12 to form a first segment
202 of reinforcement structure 20'. Concrete may be pumped into the
space between lining segment 32 and interior bore wall 12 or may be
introduced into this space by any other suitable means. Bracing
station 100 provides the bracing required to contain the liquid
concrete used to form reinforcement structure segment 202. More
particularly, bracing mechanisms 106 and formwork components 104
counteract at least a portion of the pressure of the liquid
concrete in the space between lining segment 32 and interior bore
wall 12. The liquid concrete encases (at least partially) anchoring
features 46 of anchors 34 to bond to lining segment 32. In some
embodiments, some of anchors 34 (including some of anchors 34 that
extend beyond trailing edge 38A) may be coupled to lining segment
32 after concrete is introduced to the space between lining segment
32 and interior bore wall 12, but before this concrete cures. When
the concrete in this space concrete cures, it provides a first
segment 202 of a lined reinforcement structure 20'.
[0080] As shown in FIG. 6B, the concrete introduced into this space
and that forms first reinforcement structure segment 202 may occupy
a region between trailing edge 204A and leading edge 204B and may
have an axial dimension 206. Axial dimension 206 of first
reinforcement structure segment 202 may be less than the axial
dimension 36 of lining segment 32. As explained in more detail
below, this axial dimension difference leaves a space near trailing
edge 38A of lining segment 32 that may be occupied by a subsequent
reinforcement structure segment 202 to facilitate an interleaving
offset of the transitions 60 between adjacent lining segments 32
and the transitions 208 adjacent reinforcement structure segments
202.
[0081] Once liquid concrete cures to provide first reinforcement
structure segment 202, then bracing station 100 is configured to
its retracted configuration by retracting bracing mechanisms 106 to
their respective retracted configurations. Once bracing mechanisms
106 are in their retracted configurations, then bracing station is
free to move axially independently of lining segment 32. As shown
in FIG. 6C, the axial movement mechanism then moves bracing station
axially within bore 10, leaving a first segment 202 of a lined
reinforcement structure 20' behind in bore 10.
[0082] The process is then repeated for a next lining segment 32
and a next reinforcement structure segment 202. More particularly,
as shown in FIG. 6D, a next lining segment 32 is positioned to be
engaged by bracing station 100, the axial movement mechanism and/or
some other movement mechanism places bracing station 100 into a
position where it can engage next lining segment 32 by configuring
its bracing mechanisms 106 into their extended configurations and
then the axial movement mechanism starts moving the combination of
next lining segment 32 and bracing station 100 axially within bore
10 to a location adjacent first reinforcement structure segment
202.
[0083] Then, as shown in FIG. 6E, once bracing station 100 and next
lining segment 32 are positioned roughly adjacent first
reinforcement structure segment 202, bracing station 100 and/or
lining segment 32 may be finely positioned and aligned. This fine
positioning and alignment may involve any of the techniques
discussed above for fine adjustment of the position of bracing
station 100 and/or first lining segment 32. In addition, as
discussed above, first lining segment 32 may have anchors 34 (not
shown) that extend axially beyond its trailing edge 38A. Such
axially extending anchors 34 may extend past leading edge 38B of
next lining segment 32 and may be coupled to next lining segment 32
as discussed above. This extension of anchors 34 across the
transition 60 between adjacent lining segments 32 and coupling of
anchors 34 to a plurality of lining segments 32 may help to align
and/or otherwise position the second and subsequent lining segments
32.
[0084] If the amount of extension of some of the various anchors 34
beyond trailing edge 38A of first lining segment 32 is varied (as
discussed above), then it may be easier to align and couple a first
subset of axially extending anchors 34 (e.g. the furthest extending
anchors 34) to next lining segment 32 at a first instance, then
move bracing station 100 slightly further along bore 10 in the
axial direction to align and couple a subsequent subset of axially
extending anchors 34 and repeat this process until all of axially
extending anchors 34 are aligned and coupled to next lining segment
32. Once next lining segment 32 is in place, any anchors not
already coupled to next lining segment 32 may be coupled to next
lining segment 32. In a manner similar to that of first lining
segment 2, some of such anchors 34 may extend axially beyond
trailing edge 38A of next lining segment 32.
[0085] Before introducing concrete into the space between next
lining segment 32 and interior bore wall 12, bracing station 100
may be moved axially relative to next lining segment 32 as shown in
FIG. 6F. More particularly, bracing station 100 may be moved
axially relative to next lining segment 32 such that formwork
components 104 extend axially on both sides of transition 60
between adjacent lining segments 32 and on both sides of trailing
edge 204A of first reinforcement structure segment 202. That is,
bracing station 100 may be moved axially relative to next lining
segment 32 such that leading edge 120B of formwork components 104
extends beyond transition 60 between adjacent lining segments 32
and beyond trailing edge 204A of first reinforcement structure
segment 202. Placing bracing station 100 at this location may
provide extra bracing for the transition 60 between adjacent lining
segments 32 and the transition 208 between adjacent reinforcement
structure segments 202. As discussed above, relative movement
between bracing station 100 and lining segment 32 may be effected
by retracting one or more of bracing mechanisms 106 slightly to
relax the pressure/friction fit between formwork components 104 and
lining segment 32. The relatively long axial dimension 122 of
formwork components 104 relative to axial dimension 36 of lining
segment 32 may be advantageous for this purpose.
[0086] Liquid concrete is then introduced into the space between
next lining segment 32 and interior bore wall 12 to form a next
segment 202 of reinforcement structure 20' (FIG. 6F). Concrete may
be introduced into this space by any suitable means. As discussed
above, bracing station 100 provides the bracing required to contain
the liquid concrete used to form next reinforcement structure
segment 202. The liquid concrete encases (at least partially)
anchoring features 46 of anchors 34 to bond to next lining segment
32. When the concrete in this space concrete cures, it provides a
next segment 202 of a lined reinforcement structure 20'.
[0087] As can be seen from FIG. 6F, leading edge 204B of next
reinforcement structure segment 202 extends axially beyond trailing
edge 38A of first lining segment 32. In this manner, the transition
208 between adjacent reinforcement structure segments 202 is
axially offset from transition 60 between adjacent lining segments
32. This axial offset of transition 208 between adjacent
reinforcement structure segments 202 from transition 60 between
adjacent lining segments 32 may strengthen the resultant
reinforcement structure 20' relative to aligning transition 208 and
transition 60. In some embodiments, this axial offset has a length
that is greater than 5% of the axial length 36 of lining segment
32. In some embodiments, this axial offset is greater than 10% of
the axial length 36 of lining segment 32. As can be seen from FIG.
6F, the amount of concrete used to form next reinforcement
structure 202 may be such that its trailing edge 204A is further
axially along bore 10 than trailing edge 38A of lining segment 32
to facilitate this type of offset for the next iteration.
[0088] The above-described process may be repeated as required to
form a lined reinforcement structure 20' to line bore 10.
[0089] In the above-described embodiment, reinforcement structure
20' does not comprise rebar 30. When constructing a reinforcement
structure 20 that does comprise rebar 30, a rebar lattice 28 of
rebar 30 may be pre-assembled in bore 10. Such a rebar lattice 28
may be formed by moving (i.e. causing the axial movement mechanism
to move) bracing station 100 axially within bore 10 to various
location where workers can build up rebar lattice 28. In some
embodiments, rebar lattice 28 may be completely constructed before
any concrete is introduced. In other embodiments, rebar lattice 28
may be constructed iteratively segment by segment (i.e. in the same
iterative manner as the concrete 22 of reinforcement structure 20
as described above). Advantageously, even where rebar lattice 28 is
constructed iteratively, some rebar 28 may extend in axial
directions beyond the transitions 60 between edges 38A, 38B of
adjacent lining segments 32 and/or beyond the transitions 208
between edges 204A, 204B of adjacent reinforcement structure
segments 202.
[0090] FIG. 7 is a top plan view of bore 10 after being reinforced
using a two-part lined concrete reinforcement structure 310 in
accordance with particular embodiments of the invention.
Reinforcement structure 310 comprises a first reinforcement
structure 20' that is fabricated to cover at least a portion of
interior bore wall 12 as discussed above and a secondary
reinforcement structure 320 that is constructed inside a bore
defined by interior surface 24 of first reinforcement structure
20'. Secondary reinforcement structure 320 may be assembled in a
manner similar to first reinforcement structure 20' except that
interior surface 24 of lining 26 of first reinforcement structure
20' takes the place of interior bore wall 12 for construction of
secondary reinforcement structure 320 and secondary reinforcement
structure 320 covers at least a portion of interior surface 24 of
lining 26 of first reinforcement structure 20'. Features of
secondary reinforcement structure 320 may be similar to those of
reinforcement structure 20 described above and may have similar
reference numerals, except that the reference numerals of secondary
reinforcement structure 320 are preceded by the numeral "3". Lining
26 of first reinforcement structure 20'may be fabricated from a
material to which concrete 322 of secondary reinforcement structure
320 does not bond, thereby permitting relative slidable movement
between secondary reinforcement structure 320 and interior surface
24 of lining 26 of first reinforcement structure 20' under seismic
activity and/or the like. Interior surface 24 of lining 26 of first
reinforcement structure 20' may be sufficiently smooth to permit
relative slidable movement between secondary reinforcement
structure 320 and interior surface 24 of lining 26 of first
reinforcement structure 20' under seismic activity and/or the
like.
[0091] In the illustrated embodiment, first reinforcement structure
20' is a relatively thin reinforcement structure that does not
include rebar and secondary reinforcement structure 320 is a
relatively thick reinforcement structure that includes a lattice
328 of rebar 330 that provides secondary reinforcement structure
320 with additional structural support. In the illustrated
embodiment, the cross-sectional dimensions of interior surface 224
of lining 226 of secondary reinforcement structure 320 are less
than a cross-sectional dimensions of interior surface 24 of lining
26 of first reinforcement structure 20'. To accommodate this change
in dimension it may be desirable to change formwork components 104
of bracing station 100 between the fabrication of first
reinforcement structure 20' and secondary reinforcement structure
320. For example, it may be desirable to replace the formwork
components 104 used to fabricate first reinforcement structure 20'
with formwork components 104 that are smaller and have a smaller
radius of curvature for use with construction of secondary
reinforcement structure 320. Bracing mechanisms 106 may also be
adjusted for the construction of secondary reinforcement structure
320 such that their extended configurations and possibly their
retracted configurations do not extend as far toward interior bore
wall 12 as they do for the construction of first reinforcement
structure 20'.
[0092] Compound reinforcement structure 310 comprises a pair of
subsidiary lined reinforcement structures 20' 320. It will be
appreciated that if desired, compound reinforcement structures
could be provided with more than two separate subsidiary lined
reinforcement structures.
[0093] As will be apparent to those skilled in the art in the light
of the foregoing disclosure, many alterations and modifications are
possible in the practice of this invention without departing from
the spirit or scope thereof. For example: [0094] The systems and
methods described herein are not limited to bores formed in the
ground and may be used for any bores. Non-limiting examples of
bores in which the systems and methods described herein may be
employed include bores formed in water (e.g. through rivers, lakes
and/or oceans), bores on the insides of pipes located above or
below grade and/or the like. [0095] In the embodiments illustrated
and described above, bore 10 and reinforcement structures 20
fabricated therein are generally circular in cross-section. This is
not necessary however and the systems and methods of various
embodiments described herein may be modified for use in bores
having other cross-sectional shapes and/or to construct
reinforcement structures having other cross-sectional shapes. This
may be accomplished for example, by changing the cross-sectional
shape of bracing station 100, including possibly the shape and/or
location of formwork components 104 and the shape, location and/or
movement of bracing mechanisms 106. Further, the cross-sectional
shape of reinforcement structures fabricated inside bores is not
limited to the same cross-sectional shape as that of the bore. By
way of non-limiting example, a reinforcement structure having a
rectangular cross-section may be fabricated inside a bore having a
generally circular cross-sectional shape. [0096] In the embodiments
illustrated and described above, bore 10 is vertically oriented.
This is not necessary. In other embodiments, reinforcement
structures may be fabricated in accordance with the systems and
methods of various embodiments to line bores having other
orientations. [0097] In the embodiments illustrated and described
above, reinforcement structures 20 cover an entire axial swath of
bore 10. More particularly, each reinforcement structure segment
202 covers an entire circumference of interior bore wall 12. This
is not necessary. In some embodiments, each reinforcement structure
segment can be shaped to cover a portion of an axial swath (e.g. a
portion of the circumference) of the interior bore wall. In this
sense, the "circumference" of the interior bore wall should not be
understood to be limited to bore walls of circular cross-section,
because (as discussed above), bores can have non-circular
cross-sections. A non-limiting example of an application where it
might be desirable to cover a portion of an axial swath include
covering the ceiling or upper portion of a mine shaft to prevent it
from collapsing while leaving a lower portion exposed. [0098] As
discussed above, bracing station 100 may be provided with a working
platform. In systems and methods according to some embodiments, a
working platform may be provided that is capable of moving axially
along bore 10 independently of bracing station 100. Such an
independently movable bracing station may be moved by an
independently operable axial movement mechanism. In this manner,
workers may be removed from bore 10 when bracing station 100 is
being used to brace liquid concrete as the liquid concrete cures
over a period of time. [0099] In the embodiments illustrated and
described above, bore 10 is constructed first and then subsequently
reinforced by constructing reinforcement structure 20. In other
embodiments, bore 10 may be iteratively constructed and then
reinforced. For example, a first bore segment may be excavated and
then reinforced with a first reinforcement structure segment and a
first lining segment. Then a second bore segment may be excavated
further along the bore than the first bore segment and then
reinforced with a second reinforcement structure segment and a
second lining segment. This process may be repeated to interatively
construct and reinforce a bore. [0100] Providing reinforcement
structures 20 lined by lining 26 may have several advantages over
providing bare concrete reinforcement structures. For example:
lining 26 may provide a relatively smooth surface as compared to
concrete which may provide a surface for relative movement between
subsidiary lined reinforcement structures under seismic activity
and/or the like and which may provide a relatively more hygienic
surface for transporting water or the like which may be consumed by
humans or other animals; lining 26 may be impermeable to water or
other liquids under the pressures and temperatures envisioned for
the operation of the bore and may thereby prevent water from
causing damage to rebar or the like; the material from which lining
is formed may be relatively robust to chemicals which may be
transported in the bore (as compared to concrete); and/or the like.
Accordingly, the scope of the invention is to be construed in
accordance with the substance defined by the following claims.
* * * * *