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.

Description

RELATED APPLICATIONS

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

The invention pertains to construction of bores. Particular embodiments, provide systems and methods for providing a concrete reinforced bore.

BACKGROUND

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.

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

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.

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.

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.

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.

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.

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.

Systems for providing reinforcement structures may use other curable materials in addition to or in the alternative to concrete.

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.

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.

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.

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.

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.

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.

Methods for providing reinforcement structures may use other curable materials in addition to or in the alternative to concrete.

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.

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.

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.

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.

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.

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.

The concrete used to fabricate each of the reinforcement structure segments may be allowed to cure at different times.

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

In drawings which illustrate non-limiting embodiments of the invention:

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;

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;

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;

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;

FIG. 3B is a magnified, partial top elevation view of a number of panels and anchors of the FIG. 3A lining segment;

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;

FIG. 5 is a schematic isometric view of the FIG. 4 bracing station;

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

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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′.

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.

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.

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).

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.

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.

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.

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.

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

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.

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.

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′.

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.

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.

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.

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.

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.

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.

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′.

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.

The above-described process may be repeated as required to form a lined reinforcement structure 20′ to line bore 10.

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.

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.

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′.

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.

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:

• • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.

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.