AU2013357721B2

AU2013357721B2 - Device and method for creating a foundation element

Info

Publication number: AU2013357721B2
Application number: AU2013357721A
Authority: AU
Inventors: Stefan Michael Finkenzeller
Original assignee: Bauer Maschinen GmbH
Current assignee: Bauer Maschinen GmbH
Priority date: 2012-12-12
Filing date: 2013-11-11
Publication date: 2017-08-31
Anticipated expiration: 2033-11-11
Also published as: EP2743403B1; EP2743403A1; AU2013357721A1; WO2014090490A1

Abstract

The invention relates to a device for creating a foundation element in the ground, having a tubular pile and a drilling apparatus, which comprises a drill rod, which runs inside the tubular pile and can be driven in a rotary manner, a drilling tool apparatus for removing ground material and a mixing apparatus for mixing the removed ground material with a supplied, curable medium. The tubular pile comprises a tubular base body and a mixing section arranged therebeneath, which has a larger outer diameter than the tubular base body. The drilling tool apparatus comprises at least one drilling tool, which is mounted pivotably on the drill rod and by means of which ground material can be removed in a region extending radially beyond the tubular base body inside and/or underneath the mixing section. The invention further relates to a tubular pile and a method for creating a foundation element in the ground.

Description

Device and method for producing a foundation element

The disclosure relates to a device for producing a foundation element in the ground, a drilling means, a pile tube and a method for producing a foundation element in the ground.

As far as the device is concerned the invention is based on a device with a pile tube and a drilling means having a drill rod which runs inside the pile tube and can be driven in a rotating manner, a drilling tool means for removing ground material and a mixing means for mixing the removed ground material with a supplied, hardenable medium. The pile tube comprises a tubular base body and a mixing section arranged underneath, which has a larger external diameter than the tubular base body. Such a device is particularly suitable for producing a foundation element in the bed of a body of water.

The drilling means, on which the invention is based, comprises a drill rod which can be driven in a rotating manner, a drilling tool means for removing ground material inside and/or below a pile tube which can be introduced into the ground as part of a foundation element and has a tubular base body and a mixing section arranged underneath, which has a larger external diameter than the tubular base body, and a mixing means for mixing the removed ground material with a supplied, hardenable medium.

As far as the method is concerned the invention is based on a method, in particular for producing a foundation element in the bed of a body of water, in which a pile tube having a tubular base body and a lower mixing section arranged underneath, which has a larger external diameter than the tubular base body, is introduced into the ground, ground material is removed inside the cross section of the mixing section by means of a drilling tool means driven in a rotating manner, the ground material is mixed with a supplied, hardenable medium in order to form a filling material and the pile tube is filled with the filling material in order to produce the foundation element.

Furthermore, the invention relates to a pile tube which can be introduced into the ground in order to form a foundation element, with a tubular base body and a mixing section arranged below the tubular base body, in which removed ground material can be mixed with a supplied, hardenable medium and which has a larger external diameter than the tubular base body.

It is desirable that the invention provide a device and a method for producing a foundation element, which enables a particularly efficient production of a foundation element. Furthermore, it is desirable that the invention provide a pile tube that can be used for this purpose.

In accordance with the invention there is provided a device, a drilling means, a pile tube and a method. Preferred embodiments of the invention are stated in the dependent claims.

According to the invention, there is provided a device for producing a foundation element in the ground, in particular in the bed of a body of water, with - a pile tube having a tubular base body and a mixing section arranged underneath, which has a larger external diameter than the tubular base body, and - a drilling means which comprises - a drill rod which runs inside the pile tube and can be driven in a rotating manner, - a drilling tool means for removing ground material and - a mixing means for mixing the removed ground material with a supplied, hardenable medium, wherein the drilling tool means comprises at least one drilling tool which is supported in a pivotable manner on the drill rod and with which ground material can be removed inside and/or below the mixing section in an area projecting radially beyond the tubular base body.

According to the invention, there is provided a drilling means with - a drill rod which can be driven in a rotating manner, - a drilling tool means for removing ground material inside and/or below a pile tube, wherein the pile tube can be introduced into the ground as part of a foundation element, wherein the pile tube has a tubular base body and a mixing section arranged underneath, and wherein the pile tube has a larger external diameter than the tubular base body, and - a mixing means for mixing the removed ground material with a supplied, hardenable medium, wherein the drilling tool means comprises at least one drilling tool supported in a pivotable manner on the drill rod and with which ground material can be removed inside and/or below the mixing section in an area projecting radially beyond the tubular base body.

According to the invention, there is provided a pile tube which can be introduced into the ground in order to form a foundation element, with - a tubular base body and - a mixing section arranged below the tubular base body, wherein in the mixing section removed ground material can be mixed with a supplied, hardenable medium, wherein the mixing section has a larger external diameter than the tubular base body, wherein the mixing section has a removal cross section, wherein within the removal cross section ground material can be removed with a drilling tool means capable of being driven in a rotating manner and wherein the removal cross section comprises a cross sectional area projecting radially beyond the tubular base body.

According to the invention, there is provided a method for producing a foundation element in the ground, in particular in the bed of a body of water, the method comprising: - introducing a pile tube into the ground, the pile tube having a tubular base body and a lower mixing section arranged underneath, the lower mixing section having a larger external diameter than the tubular base body, removing ground material inside a cross section of the mixing section by means of a drilling tool means driven in a rotating manner, mixing the ground material with a supplied, hardenable medium in order to form a filling material and filling the pile tube with the filling material in order to produce the foundation element, wherein by means of a drilling tool of the drilling tool means, the drilling tool being supported in a pivotable manner on a drill rod, ground material is removed in a removal cross section of the mixing section, the removal cross section comprising a cross sectional area projecting radially beyond the tubular base body. A fundamental idea of the invention resides in the fact that by means of the drilling means inserted through the pile tube a borehole is produced with a diameter which is larger than the diameter of the tubular base body of the pile tube. Thus, between the pile tube base body and the borehole wall an annular or cylindrical space is created that can be filled with the hardenable filling material. In this way, an especially stable anchoring of the pile tube in the ground is realized. The foundation element formed of pile tube and filling material has a particularly high load bearing capacity. A first aspect of the invention can be seen in the fact that the ground material removed by the drilling means is mixed with a hardenable or settable medium and in this way the filling material is produced for filling the pile tube. Hence, the production of the filling material takes place inside the pile tube, in particular in the mixing section and/or above the drilling tool means. It is therefore not necessary for the removed ground material to be initially conveyed in a time-consuming and laborious manner and for the pile tube to be refilled afterwards with a filling material produced separately. The drilling-out and sinking of the pile tube and the production of the filling material can take place simultaneously. A further aspect of the invention resides in the fact that a pile tube is used that has at its lower end a mixing section with an enlarged diameter. By preference, the mixing section has approximately the same diameter as the removal cross section, along which the ground material is removed using the drilling means.

In accordance with the invention the ground material is removed with a separate drilling means that can be secured on the pile tube. The drilling means comprises at its lower end a drilling tool means with at least one drilling tool that can be driven in a rotating manner in order to remove the ground material. The drilling tool is supported in a

pivotable manner on the drill rod in order to enlarge the removal cross section with respect to the cross section of the pile tube base body, i.e. to enable ground removal in an area stretching radially beyond the internal cross section of the pile tube base body. After the drilling tool has been folded in, it can be withdrawn completely from the pile tube.

To provide adequate space for ground removal by the drilling means the lower opening cross section of the mixing area, i.e. the internal cross section of the mixing area at the lower end thereof, is larger than the internal and/or external cross section of the pile tube base body.

In the method according to the invention the ground material is removed by means of at least one foldable drilling tool inside and/or below the mixing section in an area projecting radially beyond the tube section of the pile tube. The removed ground material is mixed with a hardenable suspension. As a result, a filling material is formed, with which the pile tube and the space between pile tube and borehole wall are filled. The pile tube remains in the ground as part of the foundation element.

The mixing means which is preferably arranged directly above the drilling tool means ensures an efficient mixing of the removed ground material with the hardenable medium which is preferably supplied in the area of the drilling tool means and/or the mixing means. By preference, the drilling tool means has a conveyor means, for instance a conveyor plate, to convey the removed ground material upwards in the direction of the mixing means.

The mixing means can have one or several mixing elements that are driven in a rotating manner. Through the actively driven mixing elements, for example mixing blades or mixing plates, an especially good mixing effect is achieved.

In a preferred embodiment provision is made in that in a folded-out state of the drilling tool the drilling tool means has a diameter which is larger than an internal diameter of the tubular base body and in that in a folded-in state of the drilling tool the drilling tool means has a diameter which is smaller than the internal diameter of the tubular base body. In the folded-in state the drilling tool means can be introduced through the tubular base body of the pile tube into the area of the mixing section or removed from the pile tube. In the folded-out state, ground removal can be implemented in a removal cross section which is larger than the internal cross section of the pile tube base body and by preference corresponding at least to the cross section of the mixing section. The foldable drilling tool can preferably be folded out into an annular, external cross sectional area of the mixing section that lies radially outside the cross section of the base body.

In another preferred embodiment provision is made in that the mixing means has at least one mixing element which is supported in a pivotable manner on the drill rod. By preference, the mixing element is supported in a rotatable manner about a horizontal pivot axis. The ground material and the supplied, hardenable medium can thus be mixed within a cross section of the mixing section which is larger than the cross section of the upper, tubular base body. The mixing element can preferably be folded out into an annular, external cross sectional area of the mixing section that lies radially outside the cross section of the base body.

By preference, the foldable drilling tool and the foldable mixing element are coupled to each other. In this manner, a folded-out state of drilling tool and mixing element can be jointly set in a particularly easy way. Likewise, drilling tool and mixing element can thus be folded in jointly.

The folding-out of the drilling tool can in particular be accomplished in that the drilling tool makes contact with the borehole bottom. Through the coupling element, by means of which the foldable mixing element is connected to the foldable drilling tool, the mixing element can be folded out together with the drilling tool in a particularly easy way. Alternatively or in addition, the folding-out can also be brought about by centrifugal forces.

To keep the drilling means during the foundation process in a defined axial position in relation to the pile tube it is preferred that the pile tube has a stop, on which the drilling means can be supported axially. The stop is preferably designed in a lower area of the tubular base body of the pile tube and can be formed as a stop ring in particular. The stop can have a sliding surface, on which a stop element of the drilling means slides along.

Furthermore, it is preferred that the drilling means has a stop element for support on the pile tube. By preference, the stop element is firmly connected to the drill rod of the drilling means and can be rotated jointly with the drill rod. The stop surface formed on the stop element preferably slides along the sliding surface of the stop of the pile tube.

By preference, in the folded-out state the drilling tool is designed for removing ground material below a tube wall of the mixing section. Thus, the drilling tool can be folded out to such an extent that it reaches underneath the tube wall of the mixing section. The cross section of the mixing section can be cut free by the drilling tool means with the folded-out drilling tool. In this way, a pile tube or mixing section without lower removal elements can be used. Due to the large removal cross section of the drilling means, which corresponds at least to the external cross section of the mixing section, the pile tube can be introduced into the ground without rotational movement.

The stability and robustness of the drilling tool means can be enhanced in that in addition to the at least one foldable drilling tool the drilling tool means has at least one drilling tool which is firmly installed on the drill rod. By preference, the stationary drilling tool is designed for removing ground material within an internal, circular drilling cross section and the foldable drilling tool is designed for removing ground material in an external, annular cross sectional area. By preference, the internal removal cross section corresponds approximately to the cross section of the tubular base body and the external, annular removal cross section corresponds to the area of the mixing section that projects radially beyond the base body.

For a reliable introduction of the filling material into the annular area around the pile tube it is preferred that the mixing section has an annular upper face, in which openings are designed, through which the ground material mixed with the supplied, hardenable medium can be passed from the mixing section into an annular space surrounding the tubular base body.

Additionally or alternatively, the mixing section can have lateral openings or apertures so that the mixing section can also be anchored reliably and/or filling material can be passed via the lateral openings into the annular space formed around the base body.

The passing-in of the filling material into the annular space around the tubular base body can be improved further in that the tubular base body has lateral openings. The lateral openings in the tubular base body are preferably designed at least in a lower section of the tubular base body but can also extend substantially along the entire length of the tubular base body.

The mixing effect within the mixing section can be improved in that on an inner wall of the mixing section at least one stationary mixing element is arranged. The mixing element can comprise e.g. a radially projecting protuberance or a plate and can in particular be arranged so as to be adapted to the position of the rotating mixing elements. By preference, the mixing element located on the inner wall is arranged below and/or above the rotating mixing element so that when interacting with the rotating mixing element a particularly efficient mixing takes place. Stationary and rotating mixing element can overlap radially.

The invention is described further hereinafter by way of preferred embodiments illustrated in the accompanying, schematic Figures, wherein shows:

Fig. 1 a perspective view of a device according to the invention;

Fig. 2 a lower section of the device according to Fig. 1 with a partially withdrawn drilling means;

Fig. 3 a lower section of the device of Fig. 1 with a drilling means in the folded-in position;

Fig. 4 a lower section of the device of Fig. 1 with a drilling means in the folded-out position;

Fig. 5 a partly sectional view of the device according to Fig. 3;

Fig. 6 a partly sectional view of the device according to Fig. 4;

Fig. 7 a view from above of a device according to the invention with a folded-in drilling means; and

Fig. 8 a view from below of a device according to the invention with a drilling means in the operating position.

Identical elements or those having the same effect are designated in all Figures with the same reference signs.

Fig. 1 shows a device 10 according to the invention. The device 10 comprises a pile tube 20 with a separate drilling means 40 arranged thereon. The pile tube 20 comprises a tubular base body 22 and a mixing section 30 arranged at the lower end thereof. The mixing section 30 has a larger cross section or diameter than the tubular base body 22. As a result, during the introduction of the pile tube 20 into the ground an annular space 12 is formed around the tubular base body 22, which extends between the tubular base body 22 and the borehole wall.

In the area of the base body 22 the pile tube 20 is provided with a plurality of openings 24 in order to pass a filling material from the internal space of the pile tube 20 into the external annular space 12.

The entire pile tube 20 with base body 22 and mixing section 30 is intended to remain in the ground as a carrying structure.

The mixing section 30 also has a plurality of openings 32, 34, with upper openings 32 being provided on an upper, annular face 31 and lateral openings 34 being provided on a tube wall 33. Through the upper and lateral openings 32, 34 a filling material can be passed efficiently from the internal space of the mixing section 30 into the annular space 12.

The lateral openings 24 and 34 in the upper base body 22 and the lower mixing section 30 are designed, in particular, as elongated holes that extend in the longitudinal direction of the pile tube 20. Between the openings 34 in the mixing section 30 vertical bridges 38 are formed that separate the openings 34 from each other. On an internal side of the tube wall 33 of the mixing section 30, by preference in the area of the vertical bridges 38, stationary mixing elements 36 are arranged that can be designed as plates.

To introduce the pile tube 20 into the ground a drilling means 40 is provided which can be secured in a releasable manner on the pile tube 20. The drilling means 40 comprises a carrying frame 42 which can be placed onto the pile tube 20 or secured in the pile tube 20. On the carrying frame 42 a drive means 44 is arranged for driving a drill rod 46 in a rotating manner.

For use underwater it is preferred that the drilling means 40 comprises a mounting suspension 43, with which the drilling means 40 can be lowered, e.g. by means of a rope, from a floating platform. To introduce the pile tube 20 into the ground a carrying structure or template that is placed onto the ground and guides the pile tube 20 can be used as a support.

At its lower end the drilling means has a drilling tool means 50 which comprises one or several stationary drilling tools 52 that are fixed on the drill rod 46. The drilling tools 52 are dimensioned such that the drilling tool means 50 can be moved in the vertical direction through the base body 22 of the pile tube 20. Hence, with the stationary drilling tools 52 ground material can only be removed in an inner area of the mixing section 30. The drilling tools 52 preferably comprise removal elements 53 arranged in the radial direction on a retaining or guide plate.

In addition to the stationary drilling tools 52 one or several pivotable drilling tools 54 are provided. The pivotable drilling tools 54 are supported by way of a pivot joint 57 on a base element 56 and can be pivoted about a horizontal axis of rotation with respect to the drill rod 46. By preference, the drilling tools 54 solely comprise removal elements 55 in a radial outer area. Hence, the pivotable drilling tools 54 allow ground removal in an outer, annular area.

The pivotable drilling tools 54 are arranged in position directly behind the stationary drilling tools 52 in the direction of rotation. In the operating position a connecting bridge that carries the radially outward lying removal tools 55 and connects them to the pivot joint 57 is located in a removal shade of the stationary drilling tool 52.

Above the drilling tools 52, 54 a mixing means 60 is provided for mixing removed ground material with a supplied, hardenable medium. The mixing means 60 comprises one or several stationary mixing elements 62 which are fixed on the drill rod 46 and have a radial extension that is smaller than or equal to the internal diameter of the base body 22 so that the drill rod 46 with the mixing elements 62 can be withdrawn axially from the pile tube 20. The stationary mixing elements 62 can in particular comprise obliquely positioned mixing plates.

In addition to the stationary mixing elements 62 one or several pivotable mixing elements 64 are provided. By way of a pivot joint 67 on a base element 66 the pivotable mixing elements 64 are supported in a rotatable manner about a horizontal axis of rotation. The axes of rotation of the pivotable drilling tools 54 and the pivotable mixing elements 64 run parallel to each other.

By way of a coupling means 70 a joint pivot movement of the drilling tools 54 and the mixing elements 64 can be realized. The coupling means 70 comprises a connecting yoke, through which a pivotable mixing element 64 is connected in each case to a pivotable drilling tool 54. The connecting yoke is pivotably hinged to both the mixing element 64 and drilling tool 54. Based on their operating position in particular, drilling tools 54 and mixing elements 64 can be pivoted in the downward direction. The respective axes of rotation are arranged directly on top of each other in the axial direction.

Above the mixing means 60 the drilling means 40 comprises a centering means 80, by means of which the drilling tool means 50 and/or the mixing means 60 is kept in a centered position inside the mixing section 30. The centering means 80 is firmly connected to the drill rod 46 and rotates jointly with the latter. In doing so, it is supported radially on the base body 22 of the pile tube 20 so that the drill rod 46 is kept in the center.

Furthermore, on the drilling means 40 a stop 48 is provided, by means of which the drill rod 46 is kept in a defined axial position. On the pile tube 20 a further stop 28 is provided which is designed in the present case as a stop ring and on which the stop 48 is supported. In this manner, the drilling means 40 rests on the stop 28 of the pile tube 20 so that a defined relative position of the drilling tool means 50 to the pile tube 20 is maintained.

At the lower end of the drill rod 46 a centering or drill bit 59 is provided which is arranged in front in the drilling direction when the drilling tool 54 is in the folded-out state.

All in all, the device according to the invention enables a particularly efficient production of a foundation element in the ground. In this process a pile tube is introduced into the ground, ground material is removed inside the pile tube, mixed with a hardenable suspension and the pile tube is anchored by means of the hardenable suspension in the ground.

Throughout the specification and the claims that follow, unless the context requires otherwise, the words “comprise” and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention.

Claims

1. A device for producing a foundation element in the ground, in particular in the bed of a body of water, with a pile tube having a tubular base body and a mixing section arranged underneath, which has a larger external diameter than the tubular base body, and a drilling means which comprises a drill rod which runs inside the pile tube and can be driven in a rotating manner, a drilling tool means for removing ground material and a mixing means for mixing the removed ground material with a supplied, hardenable medium, wherein the drilling tool means comprises at least one drilling tool which is supported in a pivotable manner on the drill rod and with which ground material can be removed inside and/or below the mixing section in an area projecting radially beyond the tubular base body.

2. The device according to claim 1, wherein in a folded-out state of the drilling tool, the drilling tool means has a diameter which is larger than an internal diameter of the tubular base body and in a folded-in state of the drilling tool, the drilling tool means has a diameter which is smaller than the internal diameter of the tubular base body.

3. The device according to claim 1, wherein in a folded-out state the drilling tool is designed for removing ground material below a tube wall of the mixing section.

4. The device according to any one of the preceding claims, wherein in addition to the at least one pivotable drilling tool, the drilling tool means has at least one further drilling tool which is firmly installed on the drill rod.

5. The device according to any one of the preceding claims, wherein the mixing means has at least one mixing element which is supported in a pivotable manner on the drill rod.

6. The device according to claim 5, wherein the pivotable drilling tool and the mixing element are coupled to each other.

7. The device according to any one of the preceding claims, wherein the pile tube has a stop, on which the drilling means can be supported axially.

8. The device according to any one of the preceding claims, wherein the drilling means has a stop for support on the pile tube.

9. The device according to any one of the preceding claims, wherein the mixing section has an annular, upper face, in which openings are designed, through which the ground material mixed with the supplied, hardenable medium can be passed from the mixing section into an annular space surrounding the tubular base body.

10. The device according to any one of the preceding claims, wherein the mixing section has lateral openings.

11. The device according to any one of the preceding claims, wherein the tubular base body has lateral openings.

12. The device according to any one of the preceding claims, wherein on an inner wall of the mixing section at least one stationary mixing element is arranged.

13. A drilling means with a drill rod which can be driven in a rotating manner, a drilling tool means for removing ground material inside and/or below a pile tube, wherein the pile tube can be introduced into the ground as part of a foundation element, wherein the pile tube has a tubular base body and a mixing section arranged underneath, and wherein the pile tube has a larger external diameter than the tubular base body, and a mixing means for mixing the removed ground material with a supplied, hardenable medium, wherein the drilling tool means comprises at least one drilling tool supported in a pivotable manner on the drill rod and with which ground material can be removed inside and/or below the mixing section in an area projecting radially beyond the tubular base body.

14. A pile tube which can be introduced into the ground in order to form a foundation element, with a tubular base body and a mixing section arranged below the tubular base body, wherein in the mixing section removed ground material can be mixed with a supplied, hardenable medium, wherein the mixing section has a larger external diameter than the tubular base body, wherein the mixing section has a removal cross section, wherein within the removal cross section ground material can be removed with a drilling tool means capable of being driven in a rotating manner and wherein the removal cross section comprises a cross sectional area projecting radially beyond the tubular base body.

15. A method for producing a foundation element in the ground, in particular in the bed of a body of water, the method comprising: - introducing a pile tube into the ground, the pile tube having a tubular base body and a lower mixing section arranged underneath, the lower mixing section having a larger external diameter than the tubular base body, - removing ground material inside a cross section of the mixing section by means of a drilling tool means driven in a rotating manner, - mixing the ground material with a supplied, hardenable medium in order to form a filling material and - filling the pile tube with the filling material in order to produce the foundation element, wherein by means of a drilling tool of the drilling tool means, the drilling tool being supported in a pivotable manner on a drill rod, ground material is removed in a removal cross section of the mixing section, the removal cross section comprising a cross sectional area projecting radially beyond the tubular base body.