EP3904602A1 - Vibrationsloser gesteinsbohrer - Google Patents

Vibrationsloser gesteinsbohrer Download PDF

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Publication number
EP3904602A1
EP3904602A1 EP21162063.8A EP21162063A EP3904602A1 EP 3904602 A1 EP3904602 A1 EP 3904602A1 EP 21162063 A EP21162063 A EP 21162063A EP 3904602 A1 EP3904602 A1 EP 3904602A1
Authority
EP
European Patent Office
Prior art keywords
drill
flight
compactor
feeder
variant
Prior art date
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Granted
Application number
EP21162063.8A
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English (en)
French (fr)
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EP3904602C0 (de
EP3904602B1 (de
Inventor
Jaron Lyell Mcmillan
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Individual
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Publication of EP3904602B1 publication Critical patent/EP3904602B1/de
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D3/00—Improving or preserving soil or rock, e.g. preserving permafrost soil
    • E02D3/12—Consolidating by placing solidifying or pore-filling substances in the soil
    • E02D3/126—Consolidating by placing solidifying or pore-filling substances in the soil and mixing by rotating blades
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/10—Deep foundations
    • E02D27/12—Pile foundations
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D3/00—Improving or preserving soil or rock, e.g. preserving permafrost soil
    • E02D3/02—Improving by compacting
    • E02D3/08—Improving by compacting by inserting stones or lost bodies, e.g. compaction piles
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D5/00—Bulkheads, piles, or other structural elements specially adapted to foundation engineering
    • E02D5/22—Piles
    • E02D5/34—Concrete or concrete-like piles cast in position ; Apparatus for making same
    • E02D5/46—Concrete or concrete-like piles cast in position ; Apparatus for making same making in situ by forcing bonding agents into gravel fillings or the soil
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/22—Rods or pipes with helical structure
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D2250/00—Production methods
    • E02D2250/0038—Production methods using an auger, i.e. continuous flight type
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D2300/00—Materials
    • E02D2300/0004—Synthetics
    • E02D2300/0018—Cement used as binder
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D2300/00—Materials
    • E02D2300/0079—Granulates
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D3/00—Improving or preserving soil or rock, e.g. preserving permafrost soil
    • E02D3/02—Improving by compacting
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D5/00—Bulkheads, piles, or other structural elements specially adapted to foundation engineering
    • E02D5/22—Piles
    • E02D5/56—Screw piles
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D5/00—Bulkheads, piles, or other structural elements specially adapted to foundation engineering
    • E02D5/22—Piles
    • E02D5/62—Compacting the soil at the footing or in or along a casing by forcing cement or like material through tubes
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D7/00—Methods or apparatus for placing sheet pile bulkheads, piles, mouldpipes, or other moulds
    • E02D7/22—Placing by screwing down
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/44—Bits with helical conveying portion, e.g. screw type bits; Augers with leading portion or with detachable parts

Definitions

  • the present invention is a drill for forming an in ground granular column or an improvement to such a device.
  • ground granular columns of aggregate are used to provide a foundation, improve drainage or stabilise the ground.
  • Some of these columns incorporate a binder such as concrete to improve their stability.
  • the drill (1) is a dual concentric drill design with a first drill (2) and a second drill (3).
  • the second drill (3) is inside the first drill (2) during the drilling phase. Once the drill (1) is at full depth the second drill (3) is engaged and extended beyond the terminal end (4) of the first drill (2).
  • the second drill (3) then feeds the granular material from the hopper (5) through a central void in the first drill (2) to the base of the column to be formed.
  • the rate of withdrawal and granular material feed rate is controlled to compact the granular material.
  • the device shown incorporates an expanded section (7) of the first drill (2) to reduce skin friction during insertion and improve radial compaction of the wall of the hole.
  • This terminally located uniformly expanded section (7) can, unless the operator is skilled, result in increased torque requirements and be problematic in hard ground.
  • the drill (1) shown in Figure 1 is shown in cross section in Figure 2 to show the engagement mechanism used to drive the second drill (3) relative to the first drill (2).
  • Figure 3 is an enlarged section of the area circled in Figure 2 which shows the drill shaft (8) of the second drill (3). Equispaced about the circumference of the drill shaft (8) are four pairs of rollers (9), each roller in a pair of rollers (9) is longitudinally separated from the other roller, i.e. each individual roller in a pair of rollers (9) is spaced along the length of the drill shaft (8).
  • Figure 4 shows a top view of the epicyclic gearbox (10) driven by the rotary head of the drilling rig.
  • the ring gear (11) and the first drill (2) rotate together and when the drill shaft (8) of the second drill (3) is engaged with the sun gear (12) then the second drill (3) rotates with the sun gear (12).
  • the sun gear (12) includes a central tunnel (13).
  • the central tunnel (13) is cross shaped and each arm of the cross is dimensioned to accept a pair of rollers (9).
  • the sun gear (12) rotates without the second drill (3) rotating.
  • the pairs of rollers (9) are pushed into the central tunnel (13) so that the sun gear (12) and second drill (3) rotate at the same time.
  • the wear and damage caused when engaging this four pair of rollers (9) configuration can require significant maintenance, and the skill required by an operator to minimise this damage is high.
  • Granular columns formed in-situ can suffer from contamination as the drill is rotated and withdrawn, this can compromise the properties of the column formed.
  • Teeth retained at the end of drill and other earth moving equipment are held in place by keepers, these keepers accept a wide variety of teeth.
  • these keepers accept a wide variety of teeth.
  • Unfortunately with the variation in properties between hard and soft ground specific teeth are required to optimise the power requirements and drill efficiency.
  • the requirement for specific teeth for each ground type increases the cost as a full set of each configuration is required on site.
  • the present invention provides an alternative to one or more of the current machines which may overcome one or more of the deficiencies of current or provide a useful choice to a consumer.
  • the present invention provides a drill with a drill flight and a drill body, where the drill body further includes one or more compactors, where each compactor present extends radially from the drill body.
  • each compactor present is a minimum of 1m to 3m from the ground terminal end of the drill, where the ground terminal end is the end of the drill configured to enter the ground first.
  • each compactor extends, at least partially, between two facing portions of the drill flight (24).
  • the facing portions are circumferentially separated by between 270° and 360°.
  • one or more compactor is longitudinally aligned with the drill.
  • one or more compactor is not longitudinally aligned with the drill.
  • the distance each compactor present extends radially from the drill body is between 0.1 and 1.2 times the flight height (FH), where the flight height (FH) is the distance between a peripheral edge of the drill flight and the drill body.
  • the drill flight has a pitch P, and each compactor present independently extends 0.1 P to 1P along the length of the drill.
  • each compactor present is, independently, at an angle of 0° to 90° to the longitudinal axis of the drill.
  • At least one compactor present is attached to the drill flight at one end.
  • at least one compactor present is not attached to the drill flight at either end.
  • the drill is a tubular drill including a drill body which is a tube and the drill flight is attached to a body outer surface of the drill body, where the body outer surface is the exposed outer surface of the drill body.
  • a first end (20) of a twin start drill (21) including a drill body (23), a drill flight (24) and an additional flight (25) is shown.
  • Figure 6 being the drill (21) shown in Figure 5 turned one quarter turn clockwise.
  • the first end (20) of the drill (21) is the end of the drill (21) that includes the ground terminal end (26).
  • the ground terminal end (26) is the terminal end of the drill that enters the ground first when drilling commences.
  • the drill body (23) is a tube which includes a body outer surface (27).
  • the body outer surface (27) is the outer, exposed, surface of the drill body (23) which the drill flights (24,25) are attached to.
  • the first and second drill flights (24,25) in this first variant are equispaced around the perimeter of the drill body (23), when viewed in cross section.
  • the additional flight (25) makes only 1/3 turn before terminating
  • the drill flight (24) has a primary section (28) at a primary flight angle (A1) and a secondary section (29) at a secondary flight angle (A2).
  • the flight angle (A1, A2) of the flight (24,25) is the angle between a line perpendicular to the longitudinal axis of the drill body (23) and a line tangential to the flight, this is sometimes called the angle of attack of a flight (24,25).
  • the drill flight (24) starts at a primary flight angle (A1) and transitions to a secondary flight angle (A2) at an angle transition point (30).
  • the angle transition between the primary flight angle (A1) and the secondary flight angle (A2) occurs at a transition distance (TD) from the ground terminal end (26).
  • the primary flight angle (A1) is expected to be from 5° and 35° and the secondary flight angle (A2) from 30° and 70° providing A2 ⁇ A1 + 10°.
  • the transition between the primary flight angle (A1) and secondary flight angle (A2) are shown in Fig. 5 and 6 as a sharp or sudden transition at the angle transition point (30).
  • the transition distance (TD) is expected to be from 0.2m to 0.6m from the ground terminal end (26).
  • FIG. 7 the first end (20) of the drill (21) is shown, in use, with a 'bubble' (33) of aggregate (32) formed around the primary section (28) of the drill (21).
  • the change in flight angle (A1, A2) occurring the transition distance (TD) from the ground terminal end (26) of the drill (21) is believed to trap a 'bubble' of aggregate (32) around the primary section (28) as the aggregate (32) encounters too much friction on the steeper secondary section (29) to move further along the body outer surface (27).
  • This bubble (33) of aggregate (32) reduces or eliminates the contaminants reaching a granular column (34) being formed by the drill (21) as it is withdrawn from the ground.
  • the first end (20) of the drill (21) is shown in partial cross-section with the drill body cavity (35) and body inner surface (36) revealed.
  • the body inner surface (36) is the exposed inner wall of the drill body (23) which forms the boundary of the drill body cavity (35).
  • the aggregate (32) flows through the drill body cavity (35) and out first end (20) and into the ground/hole formed by the drill (21).
  • the aggregate (32) moves in the direction of the arrows marked a and b.
  • the movement of the aggregate along the length of the drill body cavity (35) may be by gravity, pressurising the aggregate (32) or by conveying it by a mechanical device.
  • the pressurising of the aggregate (32) could be by simply pushing the aggregate (32) into the drill body cavity (35).
  • a blanking device (37) may be present to prevent or minimise the ingress of material into the drill body cavity (35).
  • This blanking device (37) can be any device, a single piece or multi-piece construction, that accomplishes this. In Fig. 7 this blanking device (37) is shown as a single item dislodged and embedded at the base of the 'bubble' (33) of aggregate (32).
  • a second variant is shown with a transition zone (38) rather than a transition point (30) (see Fig. 5 or Fig. 6 ).
  • the transition zone (38) is a smooth transition between the primary flight angle (A1) and secondary flight angle (A2). It is expected that this transition zone will extend circumferentially around the drill between 0.05 and 1 times the circumference.
  • a coaxially aligned feeder (40) lies within the drill body cavity (35) to feed material along the length of the drill (21).
  • This feeder (40) is shown as an auger with a feeder flight (41) and a feeder first end (42). With the feeder flight (41) being the flight of the feeder (40) and the feeder first end (42) being the terminal end of the feeder (40) located closest to the ground terminal end (26) of the drill (21).
  • the feeder (40) does not need to be an auger, it can be any device that can be used to feed the aggregate along the length of the drill (21), e.g. bucket conveyor, vibrating rod, etc.
  • This third variant may have a transition point (30) as shown in the first variant ( Fig. 5 to 7 ) or transition zone (38) as shown in the second variant (see Fig. 8 ).
  • the third variant is shown in use with the feeder (40) having been moved co-axially in relation to the drill body (23) so that the feeder first end (42) is shown extending beyond the ground terminal end (26) of the drill body (23).
  • the feeder (40) is rotated to feed aggregate (32) from the drill body cavity (35) as the drill (21) is withdrawn from the ground towards the ground surface (50) to form a granular column (34).
  • the feed rate of aggregate (32) by the feeder (40) in combination with the withdrawal rate of the drill (21) helps determine the density of the granular column (34) formed.
  • the 'bubble' (33) of aggregate (32) acts to isolate the granular column (34) being formed from being contaminated with contaminants.
  • twin start configuration has been found to penetrate the ground better than a single start/flight drill but single or multi start drills have been found to work.
  • Fig. 13 is the drill (21) shown in Fig. 12 rotated 1 ⁇ 4 turn clockwise
  • a fourth variant of the drill (21) is shown.
  • the drill (21) shown is a single start drill which includes:
  • the drill body (23), drill flight (24), first end (20) and body outer surface (27) are essentially the same as that described in variants 1 and 2 except the drill flight (24) does not change angle.
  • the drill flight (24) has a flight height (FH) of ((D-d)/2), that is the flight height (FH) is the height of the drill flight (24) above the body outer surface (27).
  • each compactor (60) is a protrusion extending away from the body outer surface (27) in the same direction as the drill flight (24).
  • Each compactor (60) includes a compactor base (61), a compactor first end (63), a compactor second end (64) and a compactor face (65).
  • the compactor base (61) is the face of the compactor (60) that is attached to (welded, glued, fused, riveted, keyed or held on by nuts & bolts, screws or similar) or coterminous with the body outer surface (27).
  • the compactor alpha face (65) is the face of the compactor (60) directly opposite the compactor base (61).
  • the compactor first end (63) is the end of the compactor (60) that is closest to the ground terminal end (26) of the drill (21) and the compactor second end (64) is the end of the compactor (60) furthest from the ground terminal end (26).
  • Each compactor (60) extends, at least partially, between two facing portions of the drill flight (24), where the facing portions can be rotationally separated by between 270° and 360°.
  • the compactors (60) shown in Fig. 12 to 14 are lengthwise aligned with the longitudinal axis of the drill (21), in other variants they may be angled in relation to the longitudinal axis of the drill (21).
  • the distance, along the longitudinal axis of the compactor (60,67,68) in question, between the compactor first end (63) and the compactor second end (64) is the compactor length (69).
  • the length each compactor (60,67,68), from compactor first end (63) to compactor second end (64), extends along the length of the drill (21) is the compactor drill length (70).
  • the compactor drill length (70) is the same as the compactor length (69).
  • the compactor length (69) is greater than the compactor drill length (70).
  • a compactor 60,67,68 is shown at different orientations, separated from the drill (21) (see Fig. 12, 13 ) with the broken line L-L representing the longitudinal axis of the drill (21).
  • the compactor (60,67.68) is angled at a compactor angle (CA) in relation to the longitudinal axis L-L and the compactor length (69) is greater than the compactor drill length (70).
  • the angle can be anything from -90° to 90°, with a 0° compactor angle (CA) being that shown in Fig. 15(i) .
  • the distance from the ground terminal end (26) to the first end (63) of the compactor (60,67) located closest to the ground terminal end (26) is the compactor-tip separation (CS).
  • FIG. 16 (i) to (vi) which is a cross sectional view of the drill body (23), with the drill flight (21) as a dashed line for clarity, along the line C-C shown in Fig. 12 in the direction of the arrows.
  • additional variants are shown.
  • FIG. 17 (i) to (x) compactors (60) of different shapes are shown, with Fig. 17 (iv) to (vi) showing compactors (60) made up of a series of sub-compactors (71), and Fig. 17(vii) to Fig. 17(x) showing side views of a portion of the drill (21) with the compactor (60) attached.
  • the shape of the compactor (60) can also be any compatible combination of the shapes shown.
  • the compactor (60) may be a strip of material, a wiggly strip or any solid geometric shape.
  • the compactor (60) is attached to the body outer surface (27) by all or part of the compactor base (61) and/or attached to the drill flight (24) by all or part of the compactor first end (63) and/or attached to the drill flight (24) by all or part of the compactor second end (64).
  • a fifth variant combining the complementary features of the first, second, or third variant in combination with the fourth variant is shown forming a compacted wall (80) granular column (34).
  • the compactors (60) form a compacted wall (80) from the spoil created during the drilling operation, this is believed to reduce the frictional effects of the wall of the hole on the drill flight above the compactors (above indicates the drill flight (24) between the compactors (60) and the ground surface (50)). Then, as the drill (21) is withdrawn with the aggregate (32) being fed, the granular column (34) is formed.
  • the flight angle (A1, A2) increases the force required to move the aggregate (32) along the drill flight (24) increases. This is believed to cause the formation of a bubble (32) of aggregate (32) around the primary section (28) which reduces the contaminant level in the granular column (34) formed.
  • the secondary flight angle (A2) and the difference between the primary flight angle (A1) and the secondary flight angle (A2) in combination with the aggregate feed rate and drill (21) withdrawal rate determines the properties of the granular column (34).
  • a sixth variant similar to the third variant is shown, in this variant a displacement unit (85) as described in WO 2014/091395 , that is it incorporates a displacement unit (85) that is engaged when the drill (21) is in use to improve the compaction of a granular column (34) (see Fig. 18 ) formed.
  • Fig. 20 a partial cutaway view of the displacement unit (85) including a guide channel (86) and one or more guidance means (87).
  • the guide channel (86) is a circumferential channel that follows a wave like path
  • the guidance means (87) is a device that rides along the guide channel (87) when the displacement unit (85) is engaged.
  • the displacement unit (85) is attached to the feeder (40), where the feeder (40) may be a second drill (88), such that, when in use, it moves the feeder (40) axially with respect to the drill (21).
  • the feeder (40) includes a feeder shaft (89) and a feeder second end (90) where:
  • the feeder shaft (89) terminates at the feeder first end (42) and the feeder second end (90).
  • the feeder second end (90) terminates at the displacement unit (85) so that when the feeder (40) is driven the displacement unit (85) is also engaged.
  • this engagement section (91) of the feeder shaft (89) includes two diametrically opposed drive units (92) where each drive unit (92) is shown as a pair of longitudinally aligned rollers or keys. In other variants there may be a single key rather than a pair of rollers or keys.
  • the engagement section (91) lies between the drive units (92) and the displacement unit (85).
  • the engagement section (91) includes an isolation unit (93) and the isolation unit (93) includes a connection unit (94) and a bias unit (95).
  • the connection unit (94) is shown as including two connection plates (96) and two sliding units (97) which span a gap between two feeder shaft sub-sections (98,99) of the feeder shaft (89).
  • Each connection plate (96) includes a longitudinally aligned connection slot (100) which is engaged with one of the sliding units (97).
  • Each connection slot (100) is shown as an obround slot through the respective connection plate (96).
  • Each sliding unit (97) is engaged with one of the connection plates (96) such that in use it can slide along the length of the complementary connection slot (100).
  • Each sliding unit (97) is shown as a bolt but it could be a T-shaped pin, mushroom headed rivet/pin or anything similar.
  • the bias unit (95) lies between the two feeder shaft sub-sections (98,99) and applies a bias force between the two feeder shaft sub-sections (98,99) to maintain them at a maximum separation distance.
  • the bias unit (95) can be a coil spring, flat spring, pneumatic cylinder, two like poles of a magnet, a combination of these or anything that similarly forces the two feeder shaft sub-sections (98,99) apart.
  • FIG. 22 a cross sectional view of an alpha gearbox (110), which is an epicyclic gearbox, is shown.
  • the alpha gearbox (110) includes an alpha sun gear (111) with an engagement channel (112).
  • the alpha sun gear (111) is similar to that shown in Fig.4 but the cross shaped central tunnel (13) is replaced with a pair of diametrically opposed engagement channels (112,113).
  • the drill (21), shown in Fig. 19 , or the drilling rig (115) shown in Fig. 1 includes a push unit (116) which is configured to push the drive units (92) into the complementary engagement channel (112,113).
  • a push unit (116) which is configured to push the drive units (92) into the complementary engagement channel (112,113).
  • the sliding unit (97) slides along complementary connection slot (100) against the bias force applied by the bias unit (95) until the drive units (92) are aligned with the complementary connection slot (100).
  • the feeder (40) is now rotationally driven by the alpha gearbox (110).
  • the bias unit (95) allows the connection unit (94) to change length to reduce shock loading and/or reduce damage to the drive units (92) or alpha sun gear (111) as the feeder (40) and/or displacement unit (85) is engaged.
  • any of the variants that include a feeder (40) can incorporate the isolation unit (93) to minimise damage when the feeder (40) drive is engaged.
  • FIG. 23 the ground terminal end (26) of a drill (21) is shown with a standard square based pyramidal keeper (120) attached to the drill flight terminal end (121), where the drill flight terminal end (121) is the end of the drill flight (24) closest to the ground terminal end (26).
  • the drill shown in Fig. 23 is a multi-start drill thus there is an additional flight (25) shown.
  • the additional flight (25) includes an additional flight terminal end (122) which is the terminal end of the additional flight (25) located closest to the ground terminal end (26).
  • a standard square based pyramidal keeper (120) is a rectangular based pyramid with a vertex, the keeper tip (123), furthest from the respective flight terminal end (121,122).
  • the standard keeper (120) (see Fig. 23 ) includes an aperture dimensioned to accept a keeper pin (124) (see Fig. 26 or 28 ).
  • a single drill tooth (130) is shown from both sides, Fig. 24 (i) is the side view from a first side and Fig. 24(ii) is the side view from the opposite side.
  • the drill tooth (130) includes a keeper recess (131), a tooth base (132) and a tooth edge (133).
  • the keeper recess (131) is a recess in the tooth base (132) dimensioned to accept a keeper (120) which includes a keeper recess tip (135).
  • the keeper recess tip (135) is the feature of the keeper recess (131) furthest from the tooth base (132).
  • the tooth edge (133) is the edge of the drill tooth (130) furthest from the tooth base (132).
  • a tooth angle (AT) is the minimum angle between the tooth base(132) and a line extending from the midpoint of the tooth base (132) and through the tooth edge (133).
  • the tooth base (132) is the face of the drill tooth (130) that faces the flight terminal end (121,122) of the associated drill flight (24) or additional flight (25) when in use.
  • the drill tooth (130) further includes a first face (136) and a second face (137) which are each faces adjacent to the tooth base (132).
  • a drill tooth (130) attached to a drill flight (24) is shown in a first configuration.
  • the first face (136) is the leading face (138) when the drill (21) is forming a hole.
  • the second face (137) is the trailing face (139).
  • a drill tooth (130) attached to a drill flight (24) is shown in a second configuration.
  • the second face (137) is the leading face (138) when the drill (21) is forming a hole.
  • the first face (136) is the trailing face (139).
  • the leading face (138) lies on a plane that is at a tooth leading angle (LA), where the tooth leading angle (LA) is the angle between a plane lying on the leading face (138) and a line parallel to the longitudinal axis of the drill (21).
  • the trailing face (139) lies on a plane that is at a tooth trailing angle (TA), where the tooth trailing angle (TA) is the angle between a plane lying on the trailing face (139) and a line parallel to the longitudinal axis of the drill (21).
  • a drill tooth (130) is shown attached to a drill flight (24) and an additional flight (25).
  • one drill tooth (130) is shown extending further than outer circumference of the drill (21) and the other less than the circumference of the body inner surface (36) (shown in dashed lines).
  • the drill tooth (130) is dimensioned such that:
  • the first configuration is more suitable to harder/denser ground and the second configuration is more suitable for softer/less dense ground.
  • the presence of a tooth improves the formation
  • keeper 120
  • keeper 120
  • other standard keeper shapes used to retain drill/excavator teeth are also envisaged.
  • the asymmetric tooth variant can be used in combination with any of the variants described, or it can be implemented separately.
  • a drill (21) combining a drill flight (24) with an angle transition point (30) or a transition zone (38) (see Fig. 8 ), an additional flight (25), compactors (60) and the asymmetric drill tooth (130) shown in Fig. 24 to 29 on each of the flights (24,25) in a first configuration Fig. 30(i) and a second configuration Fig. 30(ii) is shown.
  • Fig. 30(i) shows each drill tooth (130) in a hard/dense ground position
  • Fig. 30(ii) shows each drill tooth (130) in the soft/less dense position. In some configurations (not shown) there may be no additional flight (25).
  • This variant combines the seventh variant with the features of the sixth variant, with zero to three additional flights (25) present, and it is believed that this combination will be the optimum in many situations.
  • a hollow feeder (40) variant of the drill (21) is shown in partial cross section, omitting any gearboxes or optional components for clarity.
  • the feeder (40) is a tube that includes a feed conduit (150), where the feed conduit (150) is a void running the majority of the length of the feeder (40) with an alpha end (152) and a beta end (153).
  • alpha end (152) is close to, or coterminous with the feeder first end (42) and the beta end (153) is located close to or at the feeder second end (90).
  • the alpha end (152) or the beta end (153) may exit through the side of the feeder (40), be coterminous with the feeder first end (42) or feeder second end (90) respectively, or both exit through the side of the feeder (40) and the feeder ends (42,90).
  • the beta end (153) is fluidly connected to a bond agent conduit (156) which, when in use conveys a bonding agent (157) from a source (158) to the feeder (40).
  • a bond agent conduit (156) which, when in use conveys a bonding agent (157) from a source (158) to the feeder (40).
  • the feeder (40) in this variant, is simply an open-ended tube.
  • alpha and beta end 152,153
  • the drill (21) may include blanking devices (37) that are configured to seal the open end of the drill body (23) as the drill (21) is inserted to prevent material contaminating the bonded stone column formed.
  • the blanking devices (37) shown are small pieces of material or a disk releasably attached between the drill body (23) and the feeder (40) that are able to be dislodged when necessary but, the blanking device (37) could be a concrete/metal cone (not shown) or plate that shields the open end of the drill body (23).
  • the feeder (40) preferably includes a conduit seal (159) to seal the alpha end (152) as the drill (21) is inserted into the ground, this conduit seal (159) needs to seal against the ingress of material into the feed conduit (150).
  • this conduit seal (159) needs to seal against the ingress of material into the feed conduit (150).
  • step A1 the drill (21) is inserted into the ground.
  • the feeder (40) may be rotated, alternatively blanking device/s (37) (shown in Figure 31 ) may be present that prevent the ground material moving inside the drill body cavity (35) during this step.
  • a detrimental amount of ground material is an amount of ground material sufficient to affect the integrity of the bonded stone column (160) formed. If a conduit seal (159) is present this prevents any detrimental amount of ground material entering the feed conduit (150).
  • the blanking device (37) is a concrete cone then this should also act as conduit seal (159), in fact it is believed that a unitary conduit seal (159) and blanking device (37) may have advantages over separate devices.
  • step B1 when undertaken, the relative vertical positions of the drill body (23) and the feeder (40) is adjusted until the ground terminal end (26) and the feeder first end (42) are spaced apart (vertically displaced). This may be accomplished by moving the feeder (40) further into the ground (170), withdrawing the drill body (23) or a combination of these. If blanking devices (37) are present then these need to be dislodged or removed, for example by a momentary reversal of the feeder (40) before step B1 is undertaken, or dislodged as step B1 is undertaken.
  • the blanking device/s (37) may be retained by a breakable link (a small weld for example), be hinged/pivoted flaps, a combination of these or any other suitable means to prevent the ingress of foreign material into the drill body cavity (35). It is expected that the vertical separation between the ground terminal end (26) and the feeder first end (40) will be from 50mm to 350mm.
  • step B1 is completed then step C1 is then actioned
  • step C1 the conduit seal (159) is dislodged or removed and then one or more materials (180,181,182) are allowed to pass into the drill body cavity (35) to exit out of the ground terminal end (26).
  • a bonding agent (157) is fed through the feed conduit (150) and the feeder (40) rotated to mix the materials with the bonding agent (157) and form the bonded stone column (160) from the mixed material (191).
  • the mixed material (191) is the material (180,181,182) blended with bonding agent (157)).
  • This step will normally require that the feeder (40) is rotationally driven directly or indirectly in the direction that feeds the materials (180,181,182) to the ground terminal end (26) to start forming the bonded stone column (160).
  • the bonding agent (157) is most likely to be grout or a similar known aggregate bonding agent with or without additional additives, the materials (180,181,182) are likely to simply be aggregate that falls within a predetermined size range.
  • the materials (180,181,182) can, for example, be any or all of the following aggregate, cement + water, one or more bonding agents compatible with aggregate, aggregate + bonding agent/cement/water and concrete.
  • Step D1 is then undertaken to form the bonded stone column (160) with the desired characteristics.
  • step D1 the one or more materials (180,181,182) are fed to from the ground terminal end (26) whilst the drill (21) is withdrawn at a controlled rate and the feeder (40) is rotated at a controlled rate.
  • the required amount of bonding agent (157) is fed through the feed conduit (150) and the feeder (40) rotated to mix the materials (180,181,182) with the bonding agent (157) and force the mixed material (191) out of the drill (21).
  • the type and amount of bonding agent (157) mixed with the material (180,181,182) and measuring and controlling various drill (21) parameters a bonded stone column (160) with the desired characteristics can be formed, these characteristics include the density and porosity of the column at any point.
  • the parameters measured and controlled include one or more of rotational speed and direction of the drill (21) or feeder (40), the speed the drill (21) is withdrawn, the feed rate of the drill (21), the drill (2)/feeder (40) torque requirement, materials (180,181,182) feed rate, bonding agent (157) feed rate, etc.
  • the torque requirements of the feeder (40) and the composition fed to the ground terminal end (35) the radial and vertical compaction of the bonded stone column (160) can be varied.
  • the penetration of the materials (180,181,182) into the ground (170) surrounding the bonded stone column (160) can be controlled, thus it is possible to form a bonded stone column (160) with specific wall properties.
  • the drill (21) provides support for the ground (170) as the bonded stone column (160) is formed. With the materials (180,181,182) being forced radially and axially by the rotation of the feeder (40) and drill (21) assisting with the compaction of the surrounding ground (170) and surface of the bonded stone column (160) as it is formed.
  • the bonded stone columns (160) are expected to have the aggregate present forced out radially forming compressed walls with good ground penetration and require much less, if any, vibration. Though this radially compaction is dependent on the rotational speed and dimensions of the drill (21) and feeder (40).
  • ground terminal end (26) and feeder (40) are spaced apart then this spacing may also be varied as the drill (21) is withdrawn to modify the bonded stone column (160) properties at specific points.
  • the composition of the bonded stone column (160) By controlling the composition of the bonded stone column (160) at any point it is possible to create zones in the column which have increased density, increased porosity for drainage at specific levels, or other specific properties. It should also be noted that the aggregate size/composition/structure can be varied by feeding in different materials (180,181,182) at different rates, and varying the type and amount of bonding agent (157) fed through the feed conduit (150) can be varied at the same time.
  • the hollow feeder variant is intended to be used in combination with a variant including a primary flight angle (A1) and secondary flight angle (A2) (see Fig. 6 or 8 ) and/or one or more compactors (60) (see Fig. 12 to 18 ); in combination with any number of other compatible variants described herein.
  • A1 primary flight angle
  • A2 secondary flight angle
  • 60 compactors
  • This tension element variant includes a releasable tension device (200) including a tension unit (201) and tension link (202).
  • the tension unit (201) is intended to form part or all of the base of a stone column (34,160) (see Fig. 11 or Fig. 34 for example) formed, possibly extending beyond the side walls of the stone column (34,160) formed.
  • the tension link (202) is intended to link the base of the stone column (34,160) to a structure to reduce or eliminate the effect of uplift on that structure.
  • the tension device (200) includes a tension unit (201) and a tension link (202).
  • the tension unit (201) is shown as a flat disk extending across the ground terminal end (26) effectively sealing the open end of the body drill (23) and feeder (40), however, it may extend beyond the edge of the drill (21).
  • the tension unit (201) may be a plate of any shape (circular, elliptical, triangular, rectangular or any other polygonal shape), or even a three-dimensional object such as a cone, pyramid (truncated or not), portion of a sphere or ellipsoid, or similar.
  • the tension unit (201) may extend beyond the edges of the drill body (23), or be combined with at least one blanking device (157) to seal the ground terminal end (26).
  • the tension link (202) is shown as a rod or solid wire that lies at least partially within the feed conduit (150).
  • the tension link (202) is shown attached to and extending from the tension unit (150) to a point beyond the feeder second end (90).
  • the tension link (202) is expected to be a rod, chain, wire (solid or stranded) or a combination of these.
  • the tension link (202) may include additional surface features such as, ribs or rings (helical, linear or circumferential, continuous or broken) that are configured to engage with the material (180,181,182) of a stone column (34,160) as it is formed.
  • the tension unit (201) extends beyond the outside of the drill body (23), in others it may not completely close the drill body cavity (35). In the latter case this may require the use of blanking devices (157) to prevent unwanted material from entering the drill body cavity (35) or feed conduit (150).
  • the size of the tension unit (201) will determine the uplift overcome and as such it can be sized for specific purposes.
  • the blanking devices (157) are optional they are not shown in Figure 35 or Fig. 35A .
  • the tension unit (201) can be releasably attached to one or more of the following: the ground terminal end (26), the drill body (23), the feeder first end (42) or any other feature of the drill (21) by any suitable releasably connection type known including keyway, threaded section, magnetically, pneumatic connection, frangible connection, friction, dissolvable bonding agent or combination of these.
  • the tension unit (201) can also be held in place by tension in the tension link (202).
  • a bonded stone column (160) is formed with an integrated tension device (200) to counter or reduce the effect of uplift.
  • this variant method for the fourth embodiment includes, with some steps optional (B2 and F2 for example) or the same as for the hollow feeder variant method of use thus they are omitted for clarity (E3 for example):
  • Step A2 is similar to step A, A1 or A2, as it involves inserting the drill (21) into the ground (170) until it is at the desired depth.
  • the tension unit (201) acting alone or in combination with other features (blanking devices (37)) to minimise the ingress of undesirable material into the drill body cavity (35) and/or, where present, the feed conduit (150).
  • Step B2 or step C2 is then undertaken.
  • Step B2 is optional, though if present in this step the tension device (200) is released from the ground terminal end (26) and remains releasably attached to the feeder (40) as the ground terminal end (26) and feeder (40) are vertically spaced .apart by moving the drill body (23) and /or the feeder (40). It should be noted that releasing the tension device (200) may be accomplished by releasing the tension unit (201). Once the ground terminal end (26) and feeder (40) are at the desired spacing step C2 is undertaken. If blanking devices (37) are present then they may be dislodged in this step or any following step.
  • Step C2 involves releasing the tension unit (201) from the drill (21) and/or feeder (40), dislodging or releasing any blanking device/s (37) that is/are present and feed one or more materials (180,181,182) and/or bonding agent (157) as required to start the formation of a bonded stone column (160), then carry out step D2. Noting that if an un-bonded granular column (34) is required then no bonding agent (157) will be fed.
  • step D2 as the drill (21) is withdrawn, one or more materials (180,181,182) are allowed to pass through the drill body cavity (35).
  • the feeder (40) will be rotated to force the materials (180,181,182), which in this case can be dry materials (aggregate for example), premixed dry and bonding materials, or separate dry and bonding materials, radially outward. Some water or other fluid may be added to lubricate the dry materials. If a bonding agent (157) is to be used it can be fed in at this step at the required time (not shown in Fig. 35 / 35A see Fig. 32 ).
  • the materials (180,181,182) move into contact with at least part of the tension unit (201) to assist in retaining the tension unit (201) at the base of the column (34,160) as it forms. If a rigid tension link (202) is used this may also assist in retaining the tension unit (201) at the base of the column (34,160) as it is formed.
  • Step D2 may be followed by step E3, but this depends on whether bonding agent (137) needs to be fed into additional elements forming part of the column (34,160) (not shown in Fig. 35 / 35A see Fig. 32 ). After step D2, step F2 may be undertaken.
  • step F2 the tension link (202)) is disconnected from the drill (21) and either attached to an appropriate part of a structure (210) and tensioned, or left in a position so that once the column (190) is sufficiently bonded (where a bonded column is formed) or the structure (210) is completed it can be.
  • a bonded stone column (160) with the desired characteristics can be formed, these characteristics include the density and porosity of the column at any point.
  • the parameters measured and controlled include one or more of rotational speed and direction of the drill (21) and/or feeder (40), the speed the drill (21) is withdrawn, the feed rate of the feeder (40)/drill (21), the drill (21)/feeder (40) torque requirement, material (180,181,182) feed rate, if used the bonding agent (157) feed rate, the longitudinal separation between the ground terminal end (26) and the feeder (40), etc.
  • the radial and vertical compaction of the bonded stone column (160) can be varied.
  • the penetration of the materials (180,181,182) into the ground (170) surrounding the bonded stone column (160) can be controlled, thus it is possible to form a bonded or granular stone column (34,160) with specific wall and/or volumetric properties.
  • the steps labelled containing an A are essentially an insertion step where the drill assembly is inserted to the proper depth for the column required.
  • the steps containing a B are optional but, where present, are essentially a separation step where the position of the ground terminal end (26) relative to the feeder (40) is adjusted.
  • the steps containing a C are essentially a feed step where the steps following the separation step necessary to move from the insertion step to the formation step are undertaken.
  • the steps containing a D are essentially a formation step where the drill (21) is withdrawn from the ground (170) forming a bonded or un- bonded stone column (190).
  • the steps containing an F (F2) are optional but, where present, are a connection step where a structure (210) is attached to the bonded or granular stone column (34,160) via the tension link (202) or other connection device.
  • tension device (200) provides the link between the structure (210) and the column (190) as such an un-bonded column is able to act as ground improvement and provide a means of resisting uplift forces.
  • the tension element variant is intended to be used in combination with a variant including a primary flight angle (A1) and secondary flight angle (A2) (see Fig. 6 or 8 ) and/or one or more compactors (60) (see Fig. 12 to 18 ); in combination with any number of other compatible variants described herein.
  • A1 primary flight angle
  • A2 secondary flight angle
  • 60 compactors
  • a plan view of a sun gear unit (220) variant which includes a sun gear (12,111), an engagement unit (222) and an engagement bias unit (224) is shown.
  • This variant is intended to replace the sun gear (12,111) in an epicyclic gearbox for use with any of the variants described to reduce the damage incurred to the central tunnel (13) or engagement channels (112,113) when the feeder (40) or second drill (3) is engaged with the sun gear (12,111).
  • FIG. 37 a side view of the sun gear unit (220) is shown with the sun gear (12,111) in cross section (along line X-X in Fig. 36 in the direction of the arrows) is shown so that details of the engagement unit (222) and engagement bias unit (224) can be seen.
  • the engagement unit (222) includes an engagement tunnel (226) (shown in dashed lines) which is a co-axially aligned, open ended longitudinal void.
  • the engagement tunnel (226) (see Fig. 2, 3, 4 , 19 or 22 where needed) is the central tunnel (13), or it includes engagement channels (112,113).
  • the engagement tunnel (226) is adapted to releasably engage with complementary features on the feeder (40) (see Fig. 31 ) or second drill (3) (see Fig.2 ) so that the sun gear (12,111) can drive them.
  • the engagement unit (222) includes a first flange (231), a second flange (232) and a linking section (233).
  • the first and second flanges (231,232) form the opposite terminal ends of the engagement unit (222) with the linking section (233) lying between.
  • the linking section (233) and the first flange (231) co-terminate at the first flange sun face (234) and the linking section (233) and the second flange (232) co-terminate at the second flange sun face (235).
  • the flange sun faces (234,235) face each other, and the sun gear (12,111).
  • the sun gear (12,111) includes a sun gear (SG) first face (236) and a sun gear (SG) second face (237) which are the exposed faces of the sun gear (12,111).
  • the SG first face (236) faces the first flange sun face (234) and the SG second face (237) faces the second flange sun face (235).
  • the engagement bias unit (224) contacts both the SG first face (236) and the first flange sun face (234) applying a bias force to separate them.
  • the engagement bias unit (224) is shown as a spring, however it can be any device that applies a bias force between faces, for example, a pressurised ring, a series of small springs, one or mor leaf springs, piece of spring steel or similar resilient material, a pair of magnets with like poles facing, one or more pieces of elastomeric material; or a combination of two or more of these.
  • a single engagement bias unit (224) between the SG first face (236) and the first flange sun face (234) may be sufficient. If the engagement unit (222) is not used with the first flange uppermost then a second engagement bias device (239) (shown in dashed lines in the figure) between the SG second face (237) and the second flange sun face (235) may be needed to ensure the engagement bias device (224) still applies a bias force between the SG first face (236) and the first flange sun face (234).
  • the linking section (233) is shown as a splined cylinder with linking splines (240) which engage with matching sun gear splines (241) in the sun gear (12,111).
  • the splines (240,241) are complementary and adapted to allow differential co-axial motion of the engagement unit (222) in the direction of arrow Y in relation to the sun gear (12,111) whilst transmitting any rotational motion of the sun gear (12,111) to the engagement unit (220).
  • Figure 38 shows a series of steps, (i), (ii) and (iii) where a section of a feeder (40) which includes drive units (92) engages with engagement channels (112,113), or similar complementary features in the engagement tunnel (226).
  • the engagement bias unit (224) is shown in dashed lines for clarity.
  • step (i) the feeder is moved in the direction of arrow F while the sun gear (12,111) rotates in the direction of arrow S.
  • step (ii) the drive units (92) have contacted the first flange (231) and the force applied by the feeder (40) via the drive unit (92) to the engagement unit (222) causes the distance between the SG first face (236) and the first flange sun face (234) to decrease.
  • This reduction in distance reduces the force applied through the drive units (92) allowing the sun gear (12,111) to move in relation to the drive units (92) until they align with the complementary engagement channel (112,113).
  • the drive units (92) are shown as rollers, this is the preferred configuration, however they could be strips of material, nonrotating or rotating, or any other shape that allows them to engage with a complementary feature in the engagement tunnel (226).
  • step (iii) the drive units (92) are aligned and engaged with the complementary engagement channel (112,113).
  • the engagement bias unit (224) moves the first flange sun face (234) away from the SG first face (236) as the feeder (40) moves in the direction of arrow F until the feeder (40) is in the required position.
  • the feeder (40) is now driven by the sun gear in the direction of arrow S.
  • the damage caused by this engagement is reduced (when compared to a configuration without any form of sun gear unit (220)), especially if the feeder (40) moves erratically or suddenly in relation to the sun gear (12,111).
  • FIG 39 a variant including the preferred general features from the various earlier variants is shown in partial cross-section. This variant is believed to be the best general combination of features, it does not include the features of the hollow feeder (40) variant (see Fig. 31 ) or tension device (200) (see Fig. 33 ) as these are less general.
  • This variant includes a drill flight (24) and the additional flight (25) both with an asymmetric drill tooth (130) as this allows onsite customisation for the ground conditions. This feature is described in more detail under the heading Asymmetric Drill Tooth.
  • the drill flight (24) includes an angle transition point (30) or transition zone (38) as this is believed to provide a higher quality granular column (34) (see Fig. 18 for example). This feature is described in more detail under the First Variant, Second Variant, Third Variant and Sixth Variant headings.
  • the drill body (23) includes one or more compactors (60) to improve the wall quality of the hole and/or granular column (34) (see Fig. 18 for example). This feature is described in more detail under the Fourth and Fifth Variant headings.
  • This feature allows engagement of the feeder (40) with the sun gear unit (200) less damage than configurations without an engagement bias device (224). This feature is described in more detail under the Sun Gear Unit Variant heading.
  • range terminal value can be any decimal within the original range given, with the least significant decimal increment being a single unit, e.g. a range of 1.1 to 2.3 increments by 0.1, and a range of 2.123 to 3.4 increments by 0.001.

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AU2020255345B2 (en) 2023-07-13
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EP3854942A1 (de) 2021-07-28
EP3830345B1 (de) 2023-01-18
EP3830345A4 (de) 2021-12-22
CA3133031A1 (en) 2020-10-08
WO2020201854A1 (en) 2020-10-08
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AU2020255345A1 (en) 2021-10-28
US20220136199A1 (en) 2022-05-05

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