MINE SHAFT LINER PLATE SYSTEM AND METHOD
A liner plate structure, system and method is provided for lining of mine shaft bores, tunnels and the like. The liner plate structure includes a primary plate portion and at least one flange disposed at a side edge of the primary plate portion. A polymer seal element extends along a recess within an exterior surface of the flange.
This application is a continuation of U.S. application Ser. No. 13/407,356, filed Feb. 28, 2012, which is a continuation-in-part of U.S. application Ser. No. 13/019,372, filed Feb. 2, 2011, and claims the benefit of U.S. Provisional Application Ser. Nos. 61/301,316, filed Feb. 4, 2010, 61/369,856, filed Aug. 2, 2010 and 61/394,800, filed Oct. 20, 2010, each of which is incorporated herein by reference.
TECHNICAL FIELDThis application relates generally to liner systems for vertical mine shafts and underground tunnels and, more particularly, to liner plate system and method for providing a waterproof shaft or tunnel.
BACKGROUNDVertical mine shafts often encounter issues with water penetration, particularly when one or more vertical sections of the mine shaft pass through porous ground water containing layers. Prior attempts to address this issue include cast iron tubbing, welded steel panels, composite bolted systems and others. However, such technologies have proven expensive and timely to install.
Accordingly, it would be desirable and advantageous to provide a system and method of sealing vertical mine shafts and other types of tunnels that facilitates installation.
SUMMARYIn one aspect, a liner plate structure for use in lining shafts and tunnels includes a primary plate portion and at least one flange disposed at a side edge of the primary plate portion. A recess extends along the exterior surface of the flange and holds a seal element that is bonded to at least a bottom surface of the recess. The seal element is formed by a polymeric material applied by a plural component processing technique.
In another aspect, a liner plate structure for use in lining shafts and tunnels includes a primary plate portion having a length and height, the length greater than the height, the primary plate portion further including first, second, third and fourth side edges. First, second, third and fourth flanges respectively disposed at the first, second, third and fourth side edges, each flange having a plurality openings therein for facilitating connection to another liner plate structure. Each flange includes a respective recess that is aligned with the recess of adjacent flanges to produce a continuous recess that circumscribes the line plate structure. A continuous, seamless seal structure extends along the continuous recess and is formed by a polymeric material, where the seal structure is bonded to at least a portion of the recess.
In yet another aspect, a method of forming a plate structure for use in lining shafts and tunnels involves: utilizing a liner plate structure with a primary plate having first, second, third and fourth flanges respectively disposed at first, second, third and fourth side edges of the primary plate, each flange including a respective recess that is aligned with the recess of adjacent flanges to produce a continuous recess that circumscribes the liner plate structure; applying a seal member to the continuous recess utilizing a plural component material processing technique and in a manner such that the seal member is bonded to a portion of the recess and includes an upper portion protruding from the recess.
Referring to
The dimensions of the liner plate may vary depending upon the size of the mine shaft or tunnel into which the liner plates will be assembled, as well as other factors. However, it is contemplated that the thickness of the plate portion 12 may generally be in the range of about ¼″ to 1″ or more (e.g., such as in the range of about 2″ to 5″). In applications where the liner plate is installed to provide structural support for the shaft or tunnel wall, the plate thickness may be higher. The arcuate length or extent of a typical liner plate may be in the range of about 36″ to 72″ or more, such as up to about 216″ and the arc encompassed by that length may typically be in the range of about 18 to 36 degrees or more (e.g., such as about 40 to 180 degrees). The height of each liner plate may typically be in the range of about 24″ to 36″ or more (e.g., such as between about 42″ to 96″). The radial depth of the liner plates may be in the range of about 5″ to 10″ or more (e.g., such as in the range of about 10″ to 18″). Variations on these dimensions are possible. In some embodiments, the thickness of the flanges 14, 16, 18 and 20 will match that of the arcuate plate 12. In other embodiments the thickness of the flanges may be more or less than that of the arcuate plate.
Referring to
In this regard, and referring to
A plurality of like liner plates are assembled together to form, for example, a cylindrical mine shaft liner that is sealed against penetration by groundwater. Other mine shaft liner geometries arc possible as well, such as oval, elliptical or rectangular of other polygonal shapes. In one example, the liner plates are assembled in aligned columns and rows per
Various structures may be used to assemble adjacent liner plates together. In one example, per
In order to provide desired sealing and suitable assembly, it is contemplated that in some embodiments a typical liner plate may include electro-fusion elements along only two flanges (e.g., one of the top and bottom flanges and one of the left or right flanges). For example, referring to the cross section of
In one example, such a forced assembly arrangement could be achieved by non-symmetrical placement of the openings 40 on, for example the left and right flanges 18 and 20. Specifically, referring to
Referring to
The ends of each electro-fusion chord should terminate so they are accessible from the inward facing side of the liner plate (e.g., radially inward of the arcuate plate), making them accessible from the inside of the assembled ring of liner plates when installed. The chord ends can protrude through the gap between mating plastic sheets or extended through openings or holes in the flange or flanges and terminate at the radially inner side of the flanges of the liner plate.
Preferably, the electro-fusion process is performed after full rings of liner plates have been assembled (e.g., each time one ring is assembled or each time a specified number of rings are assembled), but could alternatively be performed as individual liner plates are assembled into place.
In an alternative embodiment, electro-fusion chords may be eliminated and adjacent flanges of the assembled/installed liner plates could be field welded in place using, for example, a down-hole field extrusion gun that applies a thermoplastic material. In other embodiments, the a true metallic weld may be applied to adjacent flanges (e.g., at the radially inner edges of the abutting flanges).
Referring to the embodiment of
The liner plates may also include a structural member 82 on the primary plate portion 12. In the illustrated embodiment, the structural member is a T-shaped member, with the base 84 of the T-shaped member welded to the inner face of the arcuate plate portion 12 and the cross or head 86 of the T disposed radially inward of the arcuate plate portion. The T-shaped structural member has a curved configuration that matches the curve of the liner plate as best seen in
In another embodiment as shown in
As seen in
Where the liner plates are made for structural support of the shaft or tunnel wall, the thickness of the steel plate making up the arcuate plate and flanges may, for example, be on the order of two to four inches, but other variations are possible. In one embodiment the thickness of the arcuate plate portion is between 25% and 75% thicker than the thickness of the flanges (e.g., 50% thicker). The arcuate length or extent of a typical structural liner plate may be in the range of about 72″ to 190″, such as about 110″ to 150″, such as about 125″ to 135″, but variations in the range of 36″ to 216″ are envisioned as well. The arc encompassed by each plate may be in the range of about 40 to 80 degrees, such as about 50 to 70 degrees, such as about 60 degrees, but variations are possible, including in the range of about 40 to 180 degrees.
The radial depth of the flanges may be on the order of about 5″ to 15″ depending on the application, such as about 8″ to 12″ (e.g. about 10″), but variations in the range of 5″ to 18″ are envisioned as well. The width or radial depth of the recess to receive the electro fusion chord will typically vary according to the radial depth of the flanges. By way of example, the width or radial depth of the recess maybe on the order of about 10% to 30% of the radial depth of the liner plate flanges.
Referring to
In one implementation, all extrusions 122 making up the ring structure are straight and the upper and lower extrusions are flexible enough to take the shape of the curved recess portions of the top and bottom flanges 14 and 16 of the liner plate. In another implementation, the top and bottom extrusions may be cold rolled into the desired curvature prior to forming the ring structure 134. Of course, other techniques for placing the extrusion in the liner plate recess may be used, such as extrusion directly into the recess.
Once the base extrusion 122 is placed in the recess, the fusion chord 120 is then applied into extrusion recesses 130. In this regard, numerous configurations for the placement pattern of the chord are possible. In one embodiment, as best seen in
Referring to
In one process, the height of the fusion assembly 180 above the surface 182 of the flange may be defined by implementing a post installation trimming operation. That is, the assembly 180 may be fully formed in the recess 80 such that layer 170 extends higher than desired. A planing type device may then be run along the surface 182 to trim the layer down to the desired height. However, other techniques could also be used.
During a fusion process, as the resistive elements in the fusion chords 120 of adjacent fusion assemblies 180 are energized and heating takes place, the polyproylene layers 170 and 174 are heated and fusion of abutting layers 170 takes place. In some embodiments, the heating may also cause the exterior sides of the layers 170 and 174 to bond to the side walls of the recess 80.
Referring now to
As a matter of practice, the secondary recess 200 may be filled with grout, only in situations where a leak is identified. Alternatively, the secondary recess 200 may always be filled with grout to provide the secondary or back-up seal for the installation.
Referring now to
In terms of overall assembly process, in one method, the liner is assembled in a top down manner in the case of a vertical mine shaft installation. A series of liner plates are assembled together with nut and bolt assemblies within the shaft to form a ring. That ring is then raised upward and connected via nut an bolt assemblies to the lower side of a previously installed ring. The exterior of the joined rings is then sprayed with polyurea to provide the first sealant barrier. Suitable equipment capable of reaching the exterior side of the assembled liner plate rings may be used for this purpose. Additional ring layers may be added in a similar fashion (by repeating the foregoing steps) to achieve the desired depth of the liner plate structure. Periodically (e.g., after every ring or every few rings are assembled), grout may be applied to the exterior of the polyurea layer in the space 52 between the bore or shaft 51 and the liner assembly by providing a temporary form structure at the bottom of the lowest ring layer and pumping grout 220 upward into the space 52 between the liner plate assemblies and the mine shaft bore wall 50. The electrofusion sealing may also be performed periodically by delivering power to the leads of the electrofusion chords. In this regard, reference is made to
It is also recognized that in any given application a mine or tunnel shaft liner system could be made up of a combination of liner plate structures with thermoplastic fusion seals and liner plate structures without thermoplastic fusion seals. For example, certain sections of the liner system could utilize the thermoplastic fusion seals in those regions where groundwater is an issue and other sections could be installed without the thermoplastic fusion seals in regions where groundwater is not an issue.
Referring now to
As shown in
In this regard, reference is made to
In one embodiment, a bonded monolithic polymer seal (BMPS) material may be used, made up of a plural component system consisting of an “isocyanate” (also known as a diisocyanate with other variations that may include: isophorone diisocyanate, methylene diphenyl diisocyanate, toluene diisocyanate or hexamethylene diisocyanate) and mixed with one or more of the following: an alcohol, an hydroxyl, a polyol, or an amine, creating a “polyurethane or polyurea” compound. An example of this material is Custom Linings 911 pure polyurea, available from Custom Linings, Inc. of Beuna Vista, Colo., but there are products that may be used.
In one embodiment, the chemical weld material may be a single or plural component system that consist of ingredients that will chemically bond thermoset polyurethane/polyurea material systems, primarily but not limited to dephenylmethane diisocyanate and methl-2-prrolidinone. An example of this material is Custom Linings SCP (although packaged as a single component, system could also be packaged as a multi-component system). Other products might alternatively be used.
Also shown in
Referring now to
As shown in
In this regard, reference is made to
Also shown in
While particular embodiments have been illustrated and described, it is to be clearly understood that the above description is intended by way of illustration and example only and is not intended to be taken by way of limitation, and that changes and modifications are possible.
Claims
1-26. (canceled)
27. A liner plate structure for use in lining shafts or tunnels, the liner plate structure comprising:
- a primary plate portion having a height and length, the length larger than the height;
- at least one flange disposed at a side edge of the primary plate portion, a seal element extending along an exterior surface of the flange, the seal element of the flange is disposed within a recess of the exterior surface of the flange, where the seal element protrudes slightly above the exterior surface of the flange, wherein a sub-recess is located to one side of the recess, the sub-recess has a depth that is less than a depth of the recess and a bottom surface that is offset below the exterior surface of the flange, and the sub-recess has one side edge in communication with the recess;
- wherein the flange, the primary plate portion, the recess and sub-recess are curved in a lengthwise direction;
- wherein the sub-recess is located to a radially inner side of the recess;
- wherein at least two spaced apart sub-recess extensions are located in the exterior surface of the flange and extend from a radially inward facing edge of the exterior surface and along the exterior surface to the sub-recess.
28. The liner plate structure of claim 27 wherein the seal element has a width that is less than a width of the recess.
29. The liner plate structure of claim 27 wherein first, second, third and fourth flanges circumscribe the primary plate portion, each flange has a corresponding recess, sub-recess and seal element, the recesses and sub-recesses align to form a circumscribing recess and sub-recess and the seal elements are joined to form a circumscribing seal element.
30. The liner plate structure of claim 27 wherein:
- a structural member protrudes from an inner side face of the primary plate portion, the structural member extends in the lengthwise direction and is also curved, the structural member being T-shaped with a head of the T located at a radially inward side of the structural member.
31. The liner plate structure of claim 27 wherein the flange has a first portion extending outwardly beyond an outer side face of the primary plate portion and a second portion extending inwardly beyond an inner side face of the primary plate portion, the first portion is substantially smaller than the second portion.
32. A liner plate structure for use in lining shafts or tunnels, the liner plate structure comprising:
- a primary plate portion;
- at least one flange disposed at a side edge of the primary plate portion, a seal element extending along an exterior surface of the flange, the seal element of the flange is disposed within a recess of the exterior surface of the flange, where the seal element protrudes slightly above the exterior surface of the flange, wherein a sub-recess is located to one side of the recess, the sub-recess has a depth that is less than a depth of the recess and a bottom surface that is offset below the exterior surface of the flange, and the sub-recess has one side edge in communication with the recess;
- the primary plate portion has a height and length, the length larger than the height, the primary plate portion is curved in the lengthwise direction;
- first, second, third and fourth flanges circumscribe the primary plate portion, each flange has a first portion extending outwardly beyond an outer side face of the primary plate portion and a second portion extending inwardly beyond an inner side face of the primary plate portion;
- wherein the flanges are welded to the primary plate portion, the first portion of each flange is substantially smaller than the second portion.
33. The liner plate structure of claim 32 wherein the primary plate portion includes at least two holes extending from an inner side face to an outer side face of the primary plate portion, each of the holes including threads.
34. A liner structure within a shaft or tunnel and formed of multiple liner plate structures according to claim 32, the liner structure comprising:
- multiple sets of liner plate structures according to claim 32, each set of liner plate structures fixed together into a respective ring to provide multiple liner plate rings, the multiple liner plate rings arranged adjacent each other along the shaft or tunnel forming a sealed structural barrier.
35. A method of assembling a liner system for lining a shaft or tunnel, the method comprising:
- joining together first and second liner plate structures, each liner plate structure having a primary plate portion and at least one flange disposed at a side edge of the primary plate portion, the flange having a recess extending along its exterior surface and holding a seal element that protrudes above the recess, the seal element formed by a polyurethane and/or polyurea material that is bonded to at least one surface of the recess;
- prior to the joining step, applying a chemical weld activator coating to at least one of (i) the seal element of the first liner plate structure and/or (ii) the seal element of the second liner plate structure; and
- during the joining step, pressing the seal element of the first liner plate structure into contact with the seal element of the second liner plate structure such that the seal elements become chemically welded to each other.
36. A method of forming a plate structure for use in lining shafts and tunnels, comprising:
- utilizing a liner plate structure with a primary plate having first, second, third and fourth flanges respectively disposed at first, second, third and fourth side edges of the primary plate, each flange including a respective recess that is aligned with the recess of adjacent flanges to produce a continuous recess that circumscribes the liner plate structure;
- applying a seal member to the continuous recess utilizing a plural component material processing technique and in a manner such that the seal member at least partially cures within the recess and is bonded to a portion of the recess and includes an upper portion protruding from the recess.
37. The method of claim 36 wherein the applying step involves an impingement mix spray process.
38. The method of claim 36 wherein the applying step involves a static mix injection process.
39. The method of claim 36 wherein prior to the applying step the recess is prepared by an abrading step.
40. The method of claim 39 wherein the abrading step is an abrasive blast spray process.
41. The method of claim 36 wherein the seal member applied via the plural component material processing technique is a polyurethane or polyurea compound.
42. The method of claim 36 wherein seal member applied via the plural component processing technique is formed by the combination of an isocyanate and one or more of an alcohol, a hydroxyl, a polyol or an amine.
Type: Application
Filed: Jun 24, 2014
Publication Date: Dec 4, 2014
Inventors: Darrell J. Sanders (Mason, OH), Vernon B. Cameron (Mason, OH), Mark J. Swarny (Buena Vista, CO)
Application Number: 14/313,314
International Classification: E21D 11/00 (20060101);