BOTTOM-SIDE SEPARATION OF AN OBJECT TO BE CUT OUT OF STONE

Abstract

There are provided a method for the bottom-side separation of a body which is to be worked out of rock (2000), in which a first part of the bottom surface of the body to be worked out of the rock (2000) is separated by removing the rock (2000) situated below the bottom surface, and a second part of the bottom surface is separated by replacing rock (2000) situated below the bottom surface with a layer system (140, 240, 440, 540) which has two unconnected separating layers (141, 142, 241, 242, 441, 442, 541, 542, 1310, 1320), with the result that the body to be worked out of the rock (2000) is supported in the region of this second part of its bottom surface by the layer system (140, 240, 440, 540), and a system (1000), which is suitable for carrying out such a method, for the bottom-side separation of a body to be worked out of a rock (2000), having an advancing unit (1100) for removing a rock layer, a discharge conveying unit (1200) for conveying away rock (2000) removed by the advancing unit (1100), a laying unit (1300) for laying a first separating layer (1310) and a second separating layer (1320) not connected to the first separating layer (1310), and a filling unit (1400) having at least one concrete feeder (1410) for filling the interspace between the bottom (1421) of the space, which is created by the removal of the rock layer, and the first separating layer (1310) with concrete, having at least one concrete feeder (1430) for filling the interspace between the roof (1441) of the space, which is created by the removal of the rock layer, and the second separating layer (1320) with concrete, and having a formwork (1450).

Claims

1. A method for bottom-side separation of an object to be cut out of stone, comprising: separating a first part of the bottom surface of the object to be cut out of the stone by removing the stone below the bottom surface; and separating a second part of the bottom surface by replacing the stone below the bottom surface with a layer system having two un-connected separating layers, so that the object to be cut out of the stone is supported in an area of the second part of the bottom area by the layer system.

2. The method according to claim 1, wherein the layer system includes two concrete layers and two separating layers disposed at a surface of one of the concrete layers which faces in a direction of an other one of the concrete layers.

3. The method according to claim 1, wherein separation of the first part of the bottom surface of the object to be cut out of stone includes: making a central tunnel; making a peripheral tunnel which intersects the central tunnel at at least one point; and making secondary tunnels that run parallel to one another, each of which produces a straight line connection between the central tunnel and the peripheral tunnel so that a plurality of column created between pairs of the secondary tunnels which are adjacent to one another, wherein separation of the second part of the bottom surface of the object to be cut out of the stone is achieved by replacing at least one stone layer of each column of the column webs with the layer system having two un-connected separating layers.

4. The method according to claim 3, wherein a direction in which the central tunnel and/or the secondary tunnels run is aligned with geologic properties of the stone.

5. The method according to claim 2, concrete used for replacing the stone is fed in from a locally fixed concrete supply unit through a substantially flat line system which is extendable.

6. The method according to claim 2, wherein at least some removed and/or replaced portions of the stone are used to prepare concrete that replaces the stone.

7. The method according to claim 3, wherein before replacing the stone, an upper border surface and a lower border surface of the stone layer to be replaced is defined in the column webs by sawing processes.

8. The method according to claim 3, wherein replacing the stone layer includes: removing a stone layer in a section of a column web, carrying away portions of the stone so that has been removed, laying a first separating layer and a second separating layer, and filling with concrete an intermediate space between a bottom of space created by removal of the stone layer in a section of one of the column webs and the first separating layer and filling with concrete the intermediate space between a roof in space created by removal of the stone layer in the section of one of the column webs and second separating layer.

9. The method according to claim 8, wherein the first separating layer is supported prior to applying concrete.

10. The method according to claim 3, wherein replacing the stone is performed in ones of the column webs that are adjacent to one another in advancement directions that are opposite to one another.

11. The method according to claim 1, wherein at least one of the separating layers is laid which has a continuous structuring in an advancement direction, and/or an intermediate layer is disposed between the separating layers which is porous or which has a continuous structuring in the advancement direction.

12. A system for bottom-side separation of an object to be cut out of stone, comprising: an advancing unit for removing a stone layer; a discharge conveying unit for carrying away stone which is removed by the advancing unit; a laying unit for laying a first separating layer and a second separating layer that is not connected to the first separating layer; and a filling unit having at least one concrete feeding unit for filling an intermediate space between a bottom of space created by removal of the stone layer and the first separating layer, the at least one concrete feeding unit filling an intermediate space between a roof of space created by removal of the stone layer and the second separating layer and a form.

13. The system according to claim 12, wherein the advancing unit, the discharge conveying unit, the laying unit or the filling unit is disposed on a tracked vehicle.

14. The system according to claim 12, wherein the advancing unit, the discharge conveying unit, the laying unit or the filling unit support or brace a tunnel wall.

15. The system according to claim 12, further comprising: at least two or more advancing unit modules that are modularly connectable with one another and placed in parallel relative to one another in a same cutting plane.

16. The method according to claim 4, wherein the direction in which the central tunnel and/or the secondary tunnels run is aligned with fissures in the stone.

17. The system according to claim 12, further comprising: at least two or more discharge conveying unit modules, laying unit modules or filling unit modules that are modularly connectable with one another and placed in parallel relative to one another in a same cutting plane.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0059] The system described herein is explained in more detail below with the aid of figures showing exemplary embodiments.

[0060] FIG. 1 is a schematic representation of the structures to be generated at the bottom surface of the object to be cut out of the stone according to the system described herein.

[0061] FIG. 2 is a schematic representation of a sawing process, with a rope saw at a column web in a cutting plane, according to the system described herein.

[0062] FIG. 3 is a schematic cross sectional representation of a system for bottom-side separation of an object to be cut out of a stone, viewed from a secondary tunnels, according to the system described herein.

[0063] FIG. 4 is a sketch illustrating the modular construction of a system, as seen from above, for the bottom-side separation of an object to be cut out of a stone, according to the system described herein.

[0064] FIG. 5a is a schematic representation of a first partial step of a variant of the replacing of a stone layer in a column web in which the removal of the stone to be replaced is done using a rope saw, from the point of view of a secondary tunnels, according to the system described herein.

[0065] FIG. 5b is a schematic representation of a second partial step of a variant of the replacing of a stone layer in a column web in which the removal of the stone to be replaced is done using a rope saw, from the point of view of a secondary tunnels, according to the system described herein.

[0066] FIG. 6a is a cross section of a column web after replacement of a stone layer sawed out by a first layer system, according to the system described herein.

[0067] FIG. 6b is a cross section of a column web after replacement of a stone layer sawed out by a second layer system, according to the system described herein.

[0068] FIG. 6c is a cross section of a column web after replacement of a stone layer sawed out by a third layer system, according to the system described herein.

[0069] FIG. 6d is a cross section of a column web in which the stone forming the column web is completely replaced by a fourth layer system, according to the system described herein.

DESCRIPTION OF VARIOUS EMBODIMENTS

[0070] FIG. 1 shows a schematic representation of the structures to be created through stone removal at the bottom surface of the object to be cut out of the stone, the structures commonly forming the first part of this bottom surface. Shown here is a view from below at a point in time at which the side walls of the object to be cut out of the stone have not yet been separated, the future wall profile sketched by a dashed line L. This corresponds to a preferred construction sequence since the separation of the bottom surface of the object is then possible without risk since the side walls are still surrounded by the peripheral stone.

[0071] A central tunnel 10 may be seen, and a peripheral tunnel 20 which in this exemplary embodiment runs in a circle, with an inner radius rl of 112.5 m and an outer radius r2 of 125 m, and secondary tunnels 30 running parallel to one another with a tunnel width b which may be 5 meters, for example. The secondary tunnels 30 in this example run at right angles to the central tunnel 10, where the respective centerlines m of two secondary tunnels 30 adjacent to one another run at a distance D from one another, which may be 25 meters, for example. The central tunnel 10 may be made accessible by way of shafts or an access tunnel, which are not shown.

[0072] An optional locally-fixed concrete supply unit 11, for example in the form of a concrete silo, may be disposed in the central tunnel 10 and for conveying material therefrom through a flexible line system 12 which is laid into a respective secondary tunnel 30 currently needing concrete and which may be extended if necessary, and which in FIG. 1 leads to a selected secondary tunnel 30 but which may be laid into other secondary tunnels 30 as the need arises. The line system 12 should run as flat as possible.

[0073] Furthermore, a conveyor belt system 13, which may also be adaptable as necessary, may be disposed in the central tunnel 10 to carry away removed or replaced stone, and which also leads into a secondary tunnel 30, where the conveyor belt system 13 may be retrofitted such that the conveyor belt system 13 leads into another secondary tunnel 30 or else branches off so that the conveyor belt system 13 may lead into a plurality of secondary tunnels 30.

[0074] As an option, the removed or replaced stone may also be broken up using a crushing system 14 disposed in the central tunnel and used directly to produce concrete in the concrete supply unit 11 so as to reduce transport requirements.

[0075] Between the secondary tunnels 30, there initially remain stone connections between the bottom surface of the object to be cut out of the stone and the surrounding stone, namely the column webs 40. In the area of these column webs, the second part of the bottom surface is then separated by replacing stone lying beneath the bottom surface using a layer system which includes two un-connected separating layers which do not lie in the plane shown in FIG. 1 and therefore are not seen in FIG. 1. Examples of such layer systems and their arrangement in a column web are explained further below with the aid of FIGS. 6a to 6e.

[0076] FIG. 2 shows a schematic representation of a cutting process, with a rope saw 50 comprising a cutting rope 51, guide pulleys 52 and a drive pulley 53 at a column web. The direction of view in FIG. 2 is identical to that in FIG. 1, but the cutting plane shown is within the current cutting plane of the rope saw 50.

[0077] Such cutting processes may on one hand be used in very stable stone in the manner shown as an example in FIGS. 5a and 5b to pull a layer system into the gap created, which may be temporarily stabilized as an option by introducing a gel, the layer system having two separating layers and an optional intermediate layer. Such layer systems are represented further below and in FIGS. 6a to 6c as examples.

[0078] On the other hand, such cutting processes may also be carried out at the height of the upper edge and/or the lower edge of a stone layer to be removed prior to the removal thereof in order to keep the roof and/or the bottom of the space created from the removal of a stone layer relatively smooth and free of broken edges. In many types of stone, and when replacing a thicker stone layer with a correspondingly thicker layer system which also includes concrete layers in particular, such as the layer systems shown in FIGS. 6d and 6e, for example, this may contribute to facilitating an improved connection of the concrete layers to this roof or bottom.

[0079] FIG. 3 shows a schematic cross-sectional representation of a system 1000 for bottom-side separation of an object to be cut out of a stone 2000, viewed from the perspective of a side tunnel 30, the system able to replace such thicker stone layers of height H, which may be 2 m, for example, using such a thicker layer system. Here, the system 1000 works its way through the stone 2000 of a column web 40 in the advancement direction V.

[0080] The system 1000 is made up of [0081] an advancing unit 1100 for removing a stone layer, the unit being designed as a tunnel boring machine, [0082] a discharge conveying unit 1200 for carrying away stone removed by the advancing unit 1100, the conveying unit being designed as a conveyor belt, [0083] a laying unit 1300 for laying a first separating layer 1310 and a second separating layer 1320 not connected to the first separating layer 1310, including a first separating layer supply roll 1330 and a second separating layer supply roll 1340, and a filling unit 1400 including a concrete feed unit 1410 for filling with concrete the intermediate space 1420 between the bottom 1421 of the space created by the removal of the stone layer and the first separating layer 1310, and including a concrete feed unit 1430 for filling with concrete the intermediate space 1440 between the roof 1441 of the space created by the removal of the stone layer and the second separating layer 1320, and including a form 1450 which closes off the intermediate spaces 1420, 1440 in the advancement direction and in the direction toward the secondary tunnels 30, thereby defining the form volume closed off in the direction opposite to the direction of advancement by the already cured concrete layers 1501, 1502.

[0084] In the embodiment according to FIG. 3, supports 1460 are provided in the form volume, more precisely in the intermediate space 1420, for supporting the first separating layer 1310, where the supports may be pushed in from the side from the secondary tunnel 30 and remain with the concrete. Also shown in the exemplary embodiment of FIG. 3 is a space 1600 between the discharge conveying unit 1200 and the advancing unit 1100 on one side and the laying unit 1300 and the filling unit 1400 on the other side, the space being accessible from the secondary tunnel 30.

[0085] The form 1450 is supported by struts 1451, 1452 in the area outside the form volume at the roof 1421 and bottom 1441.

[0086] FIG. 4 is a sketch illustrating the modular construction of a system 1000, as seen from above, for the bottom-side separation of an object to be cut out of a stone. It may be seen that the advancing unit 1100, the discharge conveying unit 1200, the laying unit 1300 and the filling unit 1400 are modularly composed of four advancing unit modules II00a-d, four discharge conveying unit modules 1200a-d, four laying unit modules 1300a-d and four filling unit modules 1400a-d, respectively, disposed in a direction perpendicular to the advancement direction next to one another in a plane in which the secondary tunnels 30 lie, which enables the system to be turned around at the end of a column web 40 for processing the next column web 40 even in relatively narrow spaces.

[0087] FIGS. 5a and 5b show a schematic representation of a variant for replacing a stone layer 2000 in a column web 40 in which the removal of the stone to be removed is done using a rope saw 50, viewed from a secondary tunnel 30.

[0088] In a first step shown in FIG. 5a, a gap 3200 is sawed in the stone 2000 of a column web 40 using the cutting rope 51, wherein a first transport bar 3300 is optionally trailedfor example pulled or pushed from behindinto the gap, the transport bar comprising a feed line 3310 for a gel fluid 3440 and a gel nozzle 3320 at the side of the bar opposite to the sawing direction VV, the gap 3200 being filled from the nozzle with gel fluid 3440. Here, the sawing direction through the stone 2000 of the column web 40 may also be the direction of a secondary tunnel 30 relative to an adjacent secondary tunnel 30.

[0089] In the second step shown in FIG. 5b, a second transport bar 3301 is then led in the sawing direction VV or in the direction opposite thereto through the gap 3200 sawed using the rope saw 50. At the front side of the transport bar 3301 in the direction of motion, there is a flushing nozzle 3312 which feeds a flushing fluid through a feed line 3311 in the case where a gel fluid 3440 had been fed to the sawed gap 3200 for the stabilization thereof so as to dissolve the gel.

[0090] Fastened to the side of the transport bar 3301 opposite to the direction of motion using fastening elements 3530, there are sealing tracks 3520, each of which includes an adhesive coating 3521, 3522 on the side of the respective element facing the stone 2000. Disposed between the sealing tracks 3520 is a non-woven material 3525 or a studded rubber mat, the material being fastened to the transport bar 3301 using a fastening element 3535. This layer system may thus be pulled into the gap 3200 by moving the transport bar 3301.

[0091] Below, with the aid of FIGS. 6a to 6e different variants of layer systems after the replacement of a stone layer of a column web 40 by the respective layer system are presented.

[0092] FIG. 6a shows a cross section of a column web 40 after replacement of a sawed out stone layer by a first layer system 140, consisting of two separating layers 141, 142, namely a lower separating layer 141 and an upper separating layer 142 which directly border one another. The lower separating layer 141 has a surface structuring in the form of grooves 143.

[0093] FIG. 6b shows a cross section of a column web 40 after replacement of a sawed-out stone layer by a second layer system 240, consisting of two separating layers 241, 242, namely a lower separating layer 241 and an upper separating layer 242, between which an intermediate layer in the form of a porous non-woven material 243 disposed directly bordering the separating layers 241 and 242. The separating layers 241 and 242 are each provided with optional adhesive coatings 3521, 3522 on the side of the layers facing the stone 2000. Instead of an intermediate layer in the form of the porous non-woven material 243, a studded rubber mat may also be used which is placed at the same location.

[0094] FIG. 6c shows a cross section of a column web 40 after replacement of a sawed out stone layer by a third layer system 440, consisting of two concrete layers 443, 444, namely a lower concrete layer 443 and an upper concrete layer 444, and two separating layers 441, 442 disposed at the surface of a respective concrete layer 443, 444 facing in the direction of the other respective concrete layer 444, 443, namely a lower separating layer 441 and an upper separating layer 442, each of which has a surface structure in the form of grooves 445, 446.

[0095] FIG. 6d shows a cross section of a column web 40 in which the stone forming the column web 40 is completely replaced by a fourth layer system 540, consisting of two concrete layers 543, 544, namely a lower concrete layer 543 and an upper concrete layer 544, and two separating layers 541, 542 each disposed at the surface of a concrete layer 543, 544 facing in the direction of the respective other concrete layer 544, 543, namely a lower separating layer 541 and an upper separating layer 542, as well as an intermediate layer 545 disposed therebetween which may again be designed as porous, for example as a non-woven fabric or with a surface structuring which is continuous in the advancement direction, for example as a grooved or studded rubber mat.

[0096] Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification and/or an attempt to put into practice the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.