AU2020200837A1

AU2020200837A1 - Process for the production of concrete block mats

Info

Publication number: AU2020200837A1
Application number: AU2020200837A
Authority: AU
Inventors: De Geeter Pieter Jan
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-02-05
Filing date: 2020-02-05
Publication date: 2020-08-20

Abstract

The invention discloses a continuous process for the creation of concrete block mats. Successive moulds are coupled together, and drawn horizontally across a vibration table and curing surface. Concrete is poured when the mould is above the vibration table. The mould is only removed once the concrete is sufficiently cured. This process can be performed using fork-lifts or similar, obviating the need for cranes. 1/4 12(a)ig 12a Fig.4 224 30ig 32 12(a 12a IVI 22g 4 2 '-onFig. 5 12(a)

Description

1/4

12(a)ig 12a

Fig.4 224

30ig 32

12(a 12a

IVI 22g 4 2

'-onFig. 5 12(a)

AUSTRALIA

Patents Act 1990

COMPLETE SPECIFICATION

Invention title:

"PROCESS FOR THE PRODUCTION OF CONCRETE BLOCK MATS"

Applicant:

DE GEETER, PIETER JAN

Associated provisional applications: 2019900360; 2019904439; 2019904806;2019904636

The following statement is a full description of the invention, including the best method of performing it known to me:

"PROCESS FOR THE PRODUCTION OF CONCRETE BLOCK MATS"

Field of the Invention

[0001] The present invention relates to the production of concrete block mats.

Background to the Invention

[0002] 'Flexmat'TM concrete blocksmats are used in many applications, including the stabilization and/ or erosion prevention of dry and 'wet' embankments and channel floors, the provision of walkways and bicycle/wheelchair tracks in public parks and beach approach areas, and as temporary (re-usable) roadways on mine sites. Such mats are described in Australian patent application number 2005203286.

[0003] Concrete block mats are formed of an array of concrete blocks set across a flexible matting sheet. Currently, such concrete block mats are made in the following manner. A suitable length of loop matting (the flexible matting sheet) is laid across a vibration table. A crane lowers steel moulds into position atop the loop matting. The moulds are then filled with concrete, and the vibration table operated to ensure an even fill. The concrete is permitted to cure until it partially sets. The moulds are then removed, using the crane, and washed ready for re-use. Finally the matting sheet with moulded concrete blocks across its top is moved by crane to a stack, where it is placed so that the concrete can fully cure.

[0004] Once the moulded concrete has been moved to the stack, the moulds and vibration table can be used again for production of another set of mats.

[0005] The present invention proposes a faster and more efficient method for the production of concrete block mats.

Summary of the Invention

[0006] According to one aspect of the present invention there is provided a method of producing concrete block mats, the method including the steps of: providing a flexible sheet having a transverse direction and a longitudinal direction, the flexible sheet having a first longitudinal end; locating a first mould onto the flexible sheet; pouring concrete into the first mould; moving the first longitudinal end of the sheet in the longitudinal direction; locating a second mould onto the flexible sheet longitudinally adjacent the first mould; and pouring concrete into the second mould.

[0007] Advantageously, this allows for the use of forklifts or similar lifting means rather than using cranes. This limits or even eliminates the vertical lifting of moulded concrete done by cranes, significantly reducing risk to workers. It will also be appreciated that the present invention also allows for a continuous casting process, rather than a batch process, providing the potential for a much faster and more efficient process.

[0008] It will be appreciated that the method can be repeated by further longitudinal movement of the sheet and placement of a third and subsequent moulds.

[0009] It will further be appreciated the second mould can be located in its longitudinal position relative to the first mould before concrete is poured into the first mould.

[0010] It is preferred that the flexible sheet is loop matting. In a preferred embodiment of the invention, the loop matting is provided in a roll arranged to unroll when pulled in the longitudinal direction.

[0011] It is preferred that the steps of pouring concrete into the mould(s) are achieved by moving the mould(s) and underlying flexible sheet in the longitudinal direction while concrete is poured from a supply having a fixed longitudinal position.

[0012] It is further preferred that the concrete supply is located above a vibrating surface, such that the moulds can be vibrated during pouring of the concrete.

[0013] The method may include the additional step of skimming the surface of the poured concrete immediately after pouring.

[0014] It is preferred that the step of locating the second mould onto the flexible sheet includes the additional step of attaching the second mould to the first mould by mould connectors. The mould connectors may be flexible wires.

[0015] The step of locating the second mould onto the flexible sheet may include the additional step of locating at least one bridging tray between the first and second mould. The bridging tray preferably includes raised side walls associated with each transverse end of the first and second mould. Advantageously, this allows for the pouring of concrete to be continuous, significantly increasing the speed of the casting process.

[0016] In a preferred embodiment, the method proposes using two first moulds adjacent each other in the transverse direction, with the flexible sheet having sufficient transverse width to accommodate two moulds arranged in this way. In this embodiment, two transversely spaced concrete supplies may be used.

[0017] The method may include the additional step of elevating a portion of the flexible sheet behind the first mould before the second mould is placed onto position. This may be done by use of a double strip beam, which can be supported by a support pedestal.

[0018] The flexible sheet may be cut between the first and second moulds once the second mould has been placed in position.

[0019] The first mould may continue to be moved in the longitudinal direction until the concrete has partially cured. The first mould may then be raised away from the flexible matting. It will be appreciated that this may be achieved using a fork-lift or similar means.

[0020] The flexible matting and partially cured concrete may then be stacked for full curing. It will be appreciated that this too may be achieved using a fork lift or similar means.

[0021] In accordance with a second aspect of the present invention there is provided a method of producing concrete block mats, the method including the steps of: providing an introductory surface, a vibration table, and a curing surface all of substantially identical height; positioning a flexible sheet atop the introductory surface; locating a first mould onto the flexible sheet; moving the first mould and flexible sheet onto the vibration table; pouring concrete into the first mould; moving the first mould, concrete and flexible sheet onto the curing surface; and allowing the concrete to cure.

[0022] The introductory surface and the curing surface are preferably formed as forward and rear extensions to the vibration table, located at the same vertical level.

[0023] It will be appreciated that the provision of surfaces at substantially identical height allows for the mould, concrete and flexible sheet to be fully supported without the need for pallets or similar load bearing members.

Brief Description of the Drawings

[0024] It will be convenient to further describe the invention with reference to preferred embodiments of the present invention. Other embodiments are possible, and consequently the particularity of the following discussion is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:

[0025] Figure 1 is a perspective of a mould traditionally used in formation of concrete block mats;

[0026] Figure 2 is a side view of a mould used within the concrete block mat forming method of the present invention;

[0027] Figure 3 is a side view of a concrete block mat forming assembly apparatus for use in the method of the present invention, shown in a first phase;

[0028] Figure 4 is a cross section from the front of the concrete block mat forming assembly apparatus in the phase of Figure 3;

[0029] Figure 5 is a plan view of a portion of the concrete block mat forming assembly apparatus in the phase of Figure 3;

[0030] Figure 6 is an enlarged side view of a portion of the concrete block mat forming assembly apparatus following the phase of Figure 3;

[0031] Figure 7 is a cross section from the front of the concrete block mat forming assembly apparatus as seen in Figure 6;

[0032] Figure 8 is a side view of the concrete block mat forming assembly apparatus of Figure 3 showing in a second phase;

[0033] Figure 9 is a plan view of a connector used in the concrete block mat forming method of the present invention;

[0034] Figure 10 is a perspective of a portion of the concrete block mat forming assembly apparatus in the phase of Figure 6;

[0035] Figure 11 is a cross section from the side of a portion of the concrete block mat forming assembly apparatus in the phase of Figure 6;

[0036] Figure 12 is a side view of the concrete block mat forming assembly apparatus of Figure 3 shown in a third phase; and

[0037] Figure 13 is a side view of a stack of concrete block mats formed using the method of the present invention.

Detailed Description of Preferred Embodiments

[0038] Referring to the Figures, Figure 1 shows a mould 10 used in the creation of concrete block mats. Concrete block mats using a mould such as that of Figure 1 have a loop matting on which is a four by eight array of concrete blocks.

[0039] Figure 2 shows a mould 12 broadly similar to the mould 10 of Figure 1. The mould 12 has an array of block forming openings 14, which have tapered sides such that the mould 12 can be readily lifted away from concrete blocks once they have partially cured. The array of block forming openings 14 extend to a height 16 about half way along the height of the mould 12. The mould 12 includes fork-lift receiving apertures 18 located above the height 16, allowing for easy movement of the mould 12 using a forklift. The remaining height of the mould 12 represents a containment strip to prevent lateral spillage.

[0040] Figure 3 shows a side view of a continuous feed process for the creation of concrete block mats, with Figures 4 and 5 showing the same process. The feed process has a longitudinal direction 20 and a transverse direction 22. The feed process includes an introductory surface 24, a vibration table 26, and a curing surface 28 aligned in a longitudinal direction, and all at the same height. The introductory surface 24 and vibration table 26 each have a longitudinal dimension similar to or slightly greater than a mould 12. The curing surface 28 has a longitudinal dimension several times that of a mould 12.

[0041] The introductory surface 24, vibration table 26, and curing surface 28 each have a transverse dimension slightly greater than that of two moulds 12 placed side-by-side.

[0042] A roll 30 of flexible sheeting being loop matting 32 is positioned at an inner longitudinal end of the introductory surface 24. The roll 30 has a transverse dimension similar to that of the introductory surface 24.

[0043] Two transversely spaced one tugger winches 34 are positioned at an outer longitudinal end of the curing surface 28.

[0044] In the method of the present invention, a length of loop matting 32 is unrolled onto the introductory surface 24. Two first moulds 12(a) are positioned side-by-side on the loop matting 32. Each first mould 12(a) is connected to an associated tugger winch 34 by means of a wire 36.

[0045] The first moulds 12(a) are pulled by means of the tugger winches 34 across the introductory surface 24 onto the vibration table 26. The loop matting 32 is allowed to unroll and move with the first mould 12(a) using friction.

[0046] As the first moulds 12(a) reach the vibration table 26 concrete is poured into the first moulds 12(a) by means of a hopper (not shown). It is anticipated that two hoppers may be used, one for each of the first moulds 12(a). The hoppers may be fixed in a longitudinal position relative to the vibration table 26, but arranged to move backwards-and-forwards in the transverse direction.

[0047] As concrete 38 is poured into the first moulds 12(a) the vibration table may be vibrated to encourage non-void settling of the concrete within the first moulds 12(a). An operator may be used for each first mould 12(a) to skim the surface of the poured concrete 38 in order to create a smooth final product.

[0048] It will be understood that the rate of flow of concrete 38 through the hoppers is calibrated to match the speed at which the first moulds 12(a) are being drawn in the longitudinal direction.

[0049] When the first moulds 12(a) have been moved longitudinally sufficiently off the introductory surface 24 to provide suitable space, a double strip beam 40 is positioned beneath the loop matting 32 'behind' the first moulds 12(a). The double strip beam 40 is aligned transversely across the loop matting 32. The double strip beam 40 may then be lifted vertically using a support pedestal 42 to generate tension within the loop matting 32. This is shown in Figures 7 and 8.

[0050] Two second moulds 12(b) are be located 'behind' the double strip beam 40, on the introductory surface 24. This is shown in Figure 8.

[0051] Once the second moulds 12(b) have been suitably positioned atop the loop matting 32, the loop matting 32 can be cut and sealed along the double strip beam 40, for instance by soldering iron. The resulting 'skirts' 44 can be folded alongside the respective first and second moulds 12(a), 12(b).

[0052] The second moulds 12(b) are then connected to the first moulds 12(a) using rigid connectors 50 as seen in Figure 9. The rigid connectors 50 allow tension from the tugger winches 34 to be transferred through to the second moulds 12(b).

[0053] A bridging tray 52 is located between each first mould 12(a) and its associated second mould 12(b). Each bridging tray 52 has raised transverse edges 54 aligned with transverse sides of the first and second moulds 12(a), 12(b).

[0054] As the first moulds 12(a) are drawn beyond the hoppers, the second moulds 12(b) are drawn onto the vibrating table 26. Any concrete 38 poured during the transition from the first moulds 12(a) to the second moulds 12(b) will be captured and contained by the bridging trays 52.

[0055] The first moulds 12(a) are drawn off the vibrating table 26, and onto the curing surface 28. They continue to be drawn along the curing surface 28 as the second moulds 12(b) are filled with concrete 38.

[0056] As the second moulds 12(b) are sufficiently moved beyond the introductory surface 24 third moulds 12(c) can be introduced in the same manner. It will be appreciated that this process can continue indefinitely, until the roll 30 of loop matting 32 is exhausted.

[0057] The curing surface 28 is dimensioned such that before the first moulds 12(a) reach the outer elongate end the poured concrete will have sufficiently cured to avoid slumping. Once the concrete 38 within the first moulds 12(a) has cured to this degree, the first moulds 12(a) can be lifted away using forklifts, by means of apertures 18. These moulds 12 can then be washed and re-used.

[0058] Forklifts can then lift the concrete block mat 60 formed by the partially cured concrete 38 on the loop matting 32 onto a stack 62 to allow for full curing before use.

[0059] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

Claims

Claims 1. A method of producing concrete block mats, the method including the steps of: providing a flexible sheet having a transverse direction and a longitudinal direction, the flexible sheet having a first longitudinal end; locating a first mould onto the flexible sheet; pouring concrete into the first mould; moving the first longitudinal end of the sheet in the longitudinal direction; locating a second mould onto the flexible sheet longitudinally adjacent the first mould; and pouring concrete into the second mould.
2. A method of producing concrete block mats as claimed in claim 1, wherein the flexible sheet is loop matting.
3. A method of producing concrete block mats as claimed in claim 2, wherein the loop matting is provided in a roll arranged to unroll when pulled in the longitudinal direction.
4. A method of producing concrete block mats as claimed in any preceding claim, wherein the steps of pouring concrete into the mould(s) are achieved by moving the mould(s) and underlying flexible sheet in the longitudinal direction while concrete is poured from a supply having a fixed longitudinal position.
5. A method of producing concrete block mats as claimed in claim 4, wherein that the concrete supply is located above a vibrating surface, such that the moulds can be vibrated during pouring of the concrete.
6. A method of producing concrete block mats as claimed in any preceding claim, wherein the method includes the additional step of skimming the surface of the poured concrete immediately after pouring.
7. A method of producing concrete block mats as claimed in any preceding claim, wherein the step of locating the second mould onto the flexible sheet includes the additional step of attaching the second mould to the first mould by mould connectors.
8. A method of producing concrete block mats as claimed in any preceding claim, wherein the step of locating the second mould onto the flexible sheet includes the additional step of locating at least one bridging tray between the first and the second mould.
9. A method of producing concrete block mats as claimed in claim 8, wherein the bridging tray includes raised side walls associated with each transverse end of the first and second mould.
10. A method of producing concrete block mats as claimed in any preceding claim, wherein two first moulds are adjacent each other in the transverse direction, with the flexible sheet having sufficient transverse width to accommodate two moulds arranged in this way.
11. A method of producing concrete block mats as claimed in any preceding claim, wherein the method includes the additional step of elevating a portion of the flexible sheet behind the first mould before the second mould is placed onto position.
12. A method of producing concrete block mats as claimed in claim 11, wherein the step of elevating the portion of the flexible sheet is done by use of a double strip beam.
13. A method of producing concrete block mats as claimed in claim 12, wherein the double strip beam is supported by a support pedestal.
14. A method of producing concrete block mats as claimed in any preceding claim, wherein the flexible sheet is cut between the first and second moulds once the second mould has been placed in position.
15. A method of producing concrete block mats as claimed in any preceding claim, wherein the first mould is continued to be moved in the longitudinal direction until the concrete has partially cured.
16. A method of producing concrete block mats, the method including the steps of: providing an introductory surface, a vibration table, and a curing surface all of substantially identical height; positioning a flexible sheet atop the introductory surface; locating a first mould onto the flexible sheet; moving the first mould and flexible sheet onto the vibration table; pouring concrete into the first mould; moving the first mould, concrete and flexible sheet onto the curing surface; and allowing the concrete to cure.

DE GEETER, PIETER JAN By his Patent Attorneys ARMOUR IP

P2345AU00