AU721855B2 - Mould - Google Patents

Description

P/00/011 28/5/91 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT p p p p.

p Name of Applicants: CSR Limited and Marecon Pty Ltd Actual Inventor(s): Address for service is: WRAY ASSOCIATES 239 Adelaide Terrace Perth, WA 6000 Attorney code: WR Invention Title: "Mould" Details of Associated Provisional Application No: P05091 filed 13 February 1997 The following statement is a full description of this invention, including the best method of performing it known to me:- -2- THIS INVENTION relates to as mould for casting a structure and to a method of manufacturing a structure using a mould.

The invention provides a mould for casting a structure in-situ on a surface, the mould comprising a plurality of mould sections and connection means for releasably connecting one mould section to another for angular movement therebetween to accommodate variations in the gradient of the surface.

Where the mould sections are connected in an assembly which provides an array of rows and columns, the mould sections in each row may be connected one to another for angular movement therebetween and the mould sections in each column may be connected one to another for angular movement .therebetween. With this arrangement, those mould sections which are spaced S.:i inwardly from the peripheral edge of the assembly are each connected to four neighbouring mould sections in a manner which accommodates angular movement between that mould section and each of the four neighbouring mould 15 sections. The effect of this arrangement is that the assembly of mould sections can accommodate variations in the gradient of the surface in two mutually perpendicular directions, one in the direction of the rows and the other in the direction of the columns.

The connection means between mould sections may comprise hinge means.

The hinge means may comprise interlocking portions angularly movable with respect to each other. Each interlocking portion may have a free end with a male portion at the free end thereof and a female portion disposed inwardly of the free end immediately adjacent the male portion.

Where a cast structure comprises a plurality of segments such as concrete blocks, the mould sections may each comprise a grid structure comprising a plurality of intersecting elongate elements. The elongate elements are preferably adapted to be releasably connected together. In this way, the mould sections can be assembled on site using the elongate elements. Additionally, -3the mould sections can be removed from the cast structure in parts; that is, the elongate elements can be individually removed from the cast structure following the casting operation.

Each elongate element may have a plurality of recesses such as mortices at intervals along the length thereof. With this arrangement, the elongate elements can be assembled in a grid formation with the mortices being located at intersections between elongate elements in the grid formation. In this way, the mortice of each element at the intersection receives the mortice of the other elongate element at the intersection such that each elongate element is accommodated in the mortice of the other elongate element at the intersection.

This provides a robust connection between the intersecting elongate elements in the grid structure for withstanding forces and other treatment to which it would normally be exposed during a casting operation.

Each elongate element may be provided with said interlocking sections at the 15 ends thereof.

The invention has been devised particularly, although not exclusively, for use in-situ during the construction of mat structures which provide concrete mattress surfaces on land. Examples of such mat structures are shown in Australian *Patent Nos. 589576 and 642965.

Such mat structures are typically manufactured in a factory environment and transported to site.

The present invention allows such mat structures to be manufactured in an environment away from a factory, conveniently in close proximity to the desired point of installation. Indeed, where the mat structures are employed for stabilisation of land, the mat structures can be manufactured in-situ.

A particular advantage of the mould according to the invention is that the mould can be used on a ground surface which is not level. This is particularly -4advantageous in circumstances where a mat structure is to be installed on an incline or a decline where the angle of inclination varies along the length thereof. The ability for the mould sections to move angularly one with respect to another allows the mould to accommodate changes in the gradient of the ground surface in two mutually perpendicular directions.

The invention also provides a method of manufacturing a mat structure comprising a flexible mat providing a base and a plurality of substantially rigid blocks mounted on one face of the mat, the method comprising the steps of: positioning a flexible mat on a surface such as the ground; "'00 10 assembling a mould as defined hereinbefore on the flexible mat; introducing a settable substance such as concrete into the mould; and removing the mould from the flexible mat after at least partial setting of the settable substance.

The invention will be better understood by reference to the following description of one specific embodiment thereof as shown in the accompanying drawings in which: Figure 1 is a plan view of a mat structure manufactured by mould according to the embodiment; Figure 2 is a schematic side view of a mould used in construction of the mat structure positioned on land to afford protection therefor; Figure 3 is a perspective view of two sections of a mould according to the embodiment in position for casting of blocks forming part of the mat structure; Figure 4 is a perspective view showing one section of the mould; Figure 5 is a detailed view showing two sections of the mould connected one to the other in angular relationship; Figure 6 is a view similar to Figure 4; and Figure 7 is a view showing intersecting elongate elements of a mould section in an exploded arrangement.

The embodiment shown in the drawings is directed to construction of a mat structure 11 on uneven ground 13. In the drawings, the mat section 11 is shown in position on an inclined area of ground having variations in gradient; 10 specifically, a first region 15, a second region 17, and a third region 19 each having different gradients.

The mat structure 11 is constructed in-situ and comprises a flexible mat 21 providing a base, and a plurality of blocks 23 mounted on the upper face of the flexible mat 21. The flexible mat 21 is positioned directly on the ground 13.

l° While the blocks 23 may be anchored to the flexible mat 21 by any suitable means, it is particularly convenient for the blocks to be anchored to the mat by means of loops which are woven or otherwise provided in the mat.

The blocks 23 are cast directly onto the mat 21 using a mould 30 according to the embodiment.

The mould 30 comprises a plurality of mould sections 31 connected one to another by connection means 35. The mould sections 31 are assembled in an array of rows and columns, with the mould sections in one column being shown in Figure 2. The mould sections 31 shown in Figure 2 are each part of respective rows which extend perpendicularly to the column appearing in the drawing.

-6- The connection means 35 allow angular movement of each mould section 31 relative to neighbouring mould sections to which it is connected so as to accommodate the variations in the gradient of the ground 13, as best shown in Figure 2.

Each mould section 31 comprises a grid structure 37 assembled from a plurality of elongate elements 39. With this arrangement, the elongate elements 39 can be delivered to site and assembled to form the grid structures. Additionally, the grid structures 37 can be disassembled by individually removing the elongate elements 39, as will be explained in more detail later.

10 The grid structure 37 defines a plurality of mould cavities 37 each for forming one of the blocks 23.

Each elongate element 39 has a series of mortices 41 at intervals along the length thereof opening onto one longitudinal side. With this arrangement, the elongate elements 39 can be assembled into a grid structure in which the :15 intersecting elongate elements are secured one to another with the mortices 41 in registration one with another, as shown in Figure 4. With the arrangement at each intersection, the appropriate mortice 41 of each intersecting elongate element is received in the appropriate mortice of the other intersecting element, as best seen in Figure 7 of the drawings. With the intersecting elongate elements 39 assembled in such a fashion, the resulting grid structure 37 is of a robust construction capable of withstanding forces and abuse to which it is likely to be exposed in casting operations.

Each elongate element 39 has an end portion 47 with the free end 49. A male portion 51 is provided at the free end and a complimentary female portion 53 is provided inwardly of the free end immediately adjacent the male portion. With this arrangement, mould sections 31 can be connected one to another with the male and female portions in the end portion 47 of the elongate elements 39 interlocking, as shown in Figure 3. This provides the connection means The manner in which the end sections 47 interlock using the male and female -7portions allows angular movement between the interconnected mould sections as previously described.

Figure 4 of the drawings illustrates mould section 31a which, when assembled with other mould sections, has a neighbouring mould section on each of its four sides. Figure 5 illustrates mould section 31a with a neighbouring mould section 31b connected to one side thereof. Figure 6 illustrates mould section 31a with a further neighbouring mould section 31c connected to a side thereof which is adjacent to the side to which mould section 31b is connected.

The connection between the mould sections 31 ensures stability of the mould during the casting operation.

Once the mould has been assembled in the manner described on the flexible mat 21, concrete can be introduced into the cavities 38 within the mould to form the blocks 23.

After the concrete has set, the elongate elements 39 can be removed individually from the cast mat structure. This provides a more easier way of removing the mould 30 from the mat structure 11 as compared with having to remove each mould section as a single unit.

0The individual elongate elements can then be transported from the site and used for construction of another mat structure at a different location.

From the foregoing, it is evident that the present embodiment provides a simple yet highly effective way of constructing a mat structure in-situ. It avoids the need to transport a complete mat structure from a factory to an installation site.

It also avoids the need for transportation of a bulky mould structure. The ability to assembly and disassemble the mould in a convenient fashion onsite and to arrange the mould to accommodate variations in the gradient of the site is particularly advantageous.

-8- It will be understood that the length of elongate elements are selected according to the requirements of the particular mat structure to be constructed and the terrain in which it is to be located.

It should be appreciated that the scope of the invention is not limited to the scope of the embodiment described.

Throughout this specification, unless the context requires otherwise, the word "comprise", or variations such as "comprises" or "comprising" 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 including method steps.

t **6 o

Claims (12)

1. A mould for casting a structure in-situ on a surface, the mould comprising a plurality of mould sections and connection means for releasably connecting one mould section to another for angular movement therebetween to accommodate variations in the gradient of the surface.

2. A mould according to claim 1 wherein the connection means between mould sections comprises hinge means.

3. A mould according to claim 2 wherein the hinge means comprises interlocking portions angularly moveable with respect to each other.

4. A mould according to claim 3wherein each interlocking portion has a male portion at the free end thereof and a female portion disposed inwardly of the free end immediately adjacent the male portion.

A mould according to any one of the preceding claims wherein the mould sections each comprise a grid structure comprising a plurality of 15 intersecting elongate elements.

6. A mould according to claim 5 wherein the elongate elements are adapted to be releasably connected together.

7. A mould according to claim 6 wherein the elongate elements each have a plurality of recesses at intervals along the length thereof, whereby the elongate elements can be assembled in a grid formation with the recesses being located at intersections between elongate elements in the grid formation, the recesses in each element at respective intersections receiving the recess in the other elongate element at the intersection such that each elongate element is accommodated in the recess of the other elongate element at the intersection.

8. A mould according to claim 7 wherein each recess comprises a mortice.

9. A mould according to any one of claims 5 to 8 wherein each elongate element is provided with said interlocking portions at the ends thereof.

A method of manufacturing a mat structure comprising a flexible mat providing a base and a plurality of substantially rigid blocks mounted on one face of the mat, the method comprising the steps of: positioning a flexible mat on a surface such as the ground; assembling a mould according to any one of claims 1 to 9 on the flexible e mat; 10 introducing a settable substance such as concrete into the mould; and removing the mould from the flexible mat after at least partial setting of the settable substance.

11. A mould substantially as herein described with reference to the accompanying drawings. 9* 11

12. A method of manufacturing a mat structure substantially as herein described. Dated this thirteenth day of February 1998. CSR LIMITED and MARECON PTY LTD Applicants Wray Associates Perth, Western Australia Patent Attorneys for the Applicants S. S. S. 555S S S 55e5*