The masonry lining of a tunnel may be described as consisting of two or more segments of circular arches combined so as to form a continuous solid ring of masonry. To direct the operations of the masons in constructing this masonry ring, templates or patterns are provided which show the exact dimensions and form of the sectional profile which it is desired to secure. These patterns or templates will vary in number and construction with the form of lining and the method of excavation adopted. Where the excavation is fully lined on all four sides, the masonry work is usually divided into three parts,—the invert or floor masonry, the side-wall masonry, and the roof-arch masonry. At least one separate pattern has to be employed in constructing each of these parts of the lining; and they are known respectively as ground molds, leading frames, and arch centers, or simply centers. In the following paragraphs the form and construction usually employed for each of these three kinds of patterns is described.
Ground Molds.
—Ground molds are employed in building the tunnel invert. They are generally constructed of 3-inch plank cut exactly to the form and dimensions of the invert masonry as shown in [Fig. 38]. To permit of convenience of handling in a restricted space, they are generally made in two parts, which are joined at the middle by means of iron fish-plates and bolts. Either one or two ground molds may be employed. Where two molds are used they are set up a short distance apart, and cords are stretched from one to the other parallel to the axis of the tunnel, by which the masons are guided in their work. Extreme care has to be taken in setting the molds to ensure that they are fixed at the proper grade, and are in a plane normal to the axis of the tunnel. Where only one ground mold is employed, the finished masonry is depended upon to supply the place of the second mold, cords being stretched from it to the single mold placed the requisite distance ahead. The leveling and centering of the molds is accomplished by means of transit and level.
Fig. 38.—Ground Mold for Constructing Tunnel Invert Masonry.
Fig. 39.—Combined Ground Mold and Leading Frame for Invert and Side Wall Masonry.
Two modifications of the form of ground mold shown by [Fig. 39] are employed. The first modification is peculiar to the English method of excavation, and consists in combining the ground mold with the leading frame for the lower part of the side walls, as shown by [Fig. 39]. The second modification is employed where the two halves or sides of the invert are built separately, and it consists simply in using one-half of the mold shown by [Fig. 38]. When the last method of constructing the invert masonry is resorted to, extreme care has to be observed in setting the half-mold in order to avoid error.
Fig. 40.—Leading Frame for Constructing Side Wall Masonry.