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 thermoplastic fusion element extends along an exterior surface of the flange. A liner structure within a shaft or tunnel includes at least first and second liner plate members assembled together, the liner plate members formed of metal plate material having respective metal surfaces in contact with each other along a plate joint. A thermoplastic fusion seal arrangement is located along the plate joint. A method of lining a mine shaft bore includes: providing a plurality of liner plate members, each liner plate member having a curved shape; assembling a first set of liner plate members into a first ring structure; assembling a second set of liner plate members into a second ring structure; mounting the second ring structure in abutting contact with the first ring structure; and forming at least one seal between the first ring structure and the second ring structure.
This application 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, the entire specification of 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 tubing, 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 thermoplastic fusion element extends along an exterior surface of the flange.
In one implementation, the thermoplastic fusion element of the flange is disposed within a recess of the exterior surface of the flange.
The thermoplastic fusion element of the flange may include a multi-layer assembly including at least one thermoplastic fusion layer at the outer side of the recess and at least one elastic polymer layer below the thermoplastic fusion layer for permitting compression of the thermoplastic fusion element within the recess.
The thermoplastic fusion layer may protrude slightly above the exterior surface of the flange, with at least one electrofusion chord element is embedded within the thermoplastic fusion layer.
In a further aspect, a liner structure within a shaft or tunnel includes at least first and second liner plate members assembled together, the liner plate members formed of metal plate material having respective metal surfaces in contact with each other along a plate joint. A thermoplastic fusion seal arrangement is located along the plate joint.
In one implementation, each metal surface includes a respective recess, the thermoplastic fusion seal arrangement formed by respective thermoplastic fusion elements within each recess, the thermoplastic fusion elements fused to each other.
A coating seal material may be located at an exterior surface of the assembled liner plate members, and a grout material located within a spaced between the coating seal material and a wall of the shaft or tunnel.
In yet a further aspect, a method of lining a mine shaft bore includes the steps of: providing a plurality of liner plate members, each liner plate member having a curved shape; assembling a first set of liner plate members into a first ring structure; assembling a second set of liner plate members into a second ring structure; mounting the second ring structure in abutting contact with the first ring structure; and forming at least one seal between the first ring structure and the second ring structure.
In still 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 plat structure. A structural member is connected to and protrudes from an inner side face of the primary plate portion, the structural member extending in the lengthwise direction and located in a central region along the height of the primary plate portion.
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 are 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 may be 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.
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. A liner plate structure for use in lining shafts and 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 thermoplastic fusion element extending along an exterior surface of the flange.
2. The liner plate structure of claim 1 wherein the thermoplastic fusion element of the flange is disposed within a recess of the exterior surface of the flange.
3. The liner plate structure of claim 2 wherein the thermoplastic fusion element of the flange comprises a multi-layer assembly including at least one thermoplastic fusion layer at the outer side of the recess and at least one elastic polymer layer below the thermoplastic fusion layer for permitting compression of the thermoplastic fusion element within the recess.
4. The liner plate structure of claim 3 wherein the thermoplastic fusion layer protrudes slightly above the exterior surface of the flange.
5. The liner plate structure of claim 3 wherein at least one electrofusion chord element is embedded within the thermoplastic fusion layer.
6. The liner plate structure of claim 2 wherein the thermoplastic fusion element has a width that is less than a width of the recess.
7. The liner plate structure of claim 2 wherein a sub-recess is located to one side of the recess.
8. The liner plate structure of claim 7 wherein the sub-recess has a depth that is less than the depth of the recess, and the sub-recess has one side edge in communication with the recess.
9. The liner plate structure of claim 8 wherein the sub-recess includes at least two spaced apart extensions, each of which extends to an inward facing edge of the flange.
10. The liner plate structure of claim 1 wherein the thermoplastic fusion element includes at least one electrofusion chord element with end portions extending inward through an opening or openings in the flange and terminating at an interior side of the liner plate structure.
11. The liner plate structure of claim 2 wherein first, second, third and fourth flanges circumscribe the primary plate portion, each flange has a corresponding recess and electrofusion element, the recesses align to form a circumscribing recess and the electrofusion elements are joined to form a circumscribing electrofusion element.
12. The liner plate structure of claim 1 wherein:
- 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;
- 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.
13. The liner plate structure of claim 1 wherein the primary plate portion and flange are both formed of metal plate material, the flange metallurgically welded to the primary plate portion.
14. The liner plate structure of claim 1 wherein
- 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.
15. The liner plate structure of claim 14 wherein the flanges are welded to the primary plate portion, the first portion of each flange is substantially smaller than the second portion.
16. The liner plate structure of claim 1 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.
17. A liner structure within a shaft or tunnel, the liner structure comprising:
- at least first and second liner plate members assembled together, the liner plate members formed of metal plate material having respective metal surfaces in contact with each other along a plate joint; and
- a thermoplastic fusion seal arrangement along the plate joint.
18. The liner structure of claim 17 wherein
- each metal surface includes a respective recess, the thermoplastic fusion seal arrangement formed by respective thermoplastic fusion elements within each recess, the thermoplastic fusion elements fused to each other.
19. The liner structure of claim 18 further comprising
- a coating seal material located at an exterior surface of the assembled liner plate members.
20. The liner structure of claim 19 further comprising
- a grout material located within a spaced between the coating seal material and a wall of the shaft or tunnel.
21. The liner structure of claim 18 wherein:
- each liner plate member includes a structural member protruding from an inner side face of the liner plate member;
- an inner liner system connected to the structural members of the liner plate members.
22. A method of lining a mine shaft bore, the method comprising:
- providing a plurality of liner plate members, each liner plate member having a curved shape;
- assembling a first set of liner plate members into a first ring structure;
- assembling a second set of liner plate members into a second ring structure;
- mounting the second ring structure in abutting contact with the first ring structure; and
- forming at least one seal between the first ring structure and the second ring structure.
23. The method of claim 22 wherein the forming step involves energizing electrofusion chord members located on both the first ring structure and the second ring structure.
24. The method of claim 23 wherein the forming step includes applying a coating along an exterior surface of the joined first and second ring structures.
25. The method of claim 22 including
- applying a grout material into a space between the exterior of the joined ring structures and the mine shaft bore.
26. A liner plate structure for use in lining shafts and tunnels, the liner plate structure comprising:
- 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 plat structure;
- a structural member connected to and protruding from an inner side face of the primary plate portion, the structural member extending in the lengthwise direction and located in a central region along the height of the primary plate portion.
27. The liner plate structure of claim 26 wherein the primary plate portion includes at least one hole extending from the inner side face to an outer side face of the primary plate portion, the hole including threads for receiving a threaded plug.
28. The liner plate structure of claim 27 wherein each flange includes a first flange portion overhanging the interior side face of the primary plate portion and a second flange portion overhanging and exterior side face of the primary plate portion, the overhang of the first flange portion larger than the overhang of the second flange portion.
Type: Application
Filed: Feb 2, 2011
Publication Date: Aug 4, 2011
Inventor: Darrell J. Sanders (Mason, OH)
Application Number: 13/019,372
International Classification: E21D 11/15 (20060101); E21D 11/00 (20060101);