EP4775733A1

EP4775733A1 - Permanent formwork system for creating wall structures in tidal zones and underwater

Info

Publication number: EP4775733A1
Application number: EP25755317.2A
Authority: EP
Inventors: Nikita SHCHERBINA
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-02-14
Filing date: 2025-02-11
Publication date: 2026-07-15
Also published as: AU2025223013A1; WO2025174273A1

Abstract

The invention relates to the field of construction, namely to formwork, and represents a permanent beam-and-node formwork system for casting reinforced concrete, including underwater and in tidal zones, for the construction of concrete wall structures, including retaining walls, as well as coastal protection hydraulic structures. The technical result achieved by the patented system lies in the ability to construct wall structures of complex shapes for coastal (in the tidal zone) and/or underwater structures, whilst ensuring the strength and rigidity of the entire structure, as well as the stability of the walls in vertical position. The proposed technical result is achieved by means of a permanent formwork system for creating concrete retaining wall structures underwater and in the tidal zone, comprising a stack of horizontally laid pipes held together by frame elements, whereby some or all of the pipes in the stack are connected to a manifold, representing a pipe section with sockets arranged in a row at fixed intervals for connecting the pipes of the stack, and the frame consists of column pipes and connecting unit elements, wherein the connecting unit elements are designed as hollow three-dimensional bodies with sockets oriented at angles to one another, some of which are blind-ended, whilst others have pipes arranged therein.

Description

Technical field.

The invention relates to the field of construction, namely to formwork, and represents a permanent beam-and-node formwork system for casting reinforced concrete, including underwater and in tidal zones, for the construction of concrete protecting wall structures, including retaining walls, as well as coastal protection hydraulic structures.

Prior art.

From the prior art are known removable and non-removable formwork for forming "wall"-type concrete structures and various methods of adjoining such walls to each other (angle, tee, cross-joint), manufactured from steel, plywood, fibre-reinforced concrete, foam plastics, glued and pressed sawdust etc.
For example, known is a non-removable formwork unit, comprising formwork panels connected to a three-dimensional reinforcing lattice frame made of tubular elements, and lattice nodes in the form of spherical elements connected to the formwork panels, in which are formed sockets with internal threads, and the tubes are provided with tips arranged along their longitudinal axis, having a threaded cantilevered projection for insertion into the sockets of the spherical elements ( RU 2029840 C1, published 27.02.1995 ).
Also known is a non-removable decorative formwork representing spatially arranged flat elements that delimit at least a part of the outer contour of the object being constructed, wherein said flat elements are fastened together to form a space between them for accommodating reinforcement and for filling with a flowable material capable of hardening, wherein said flat elements are made of thin-gauge steel and constitute sections of the outer contour of the object being manufactured, some of which are designed to be fastened to the reinforcement to form a part of the surface of the object being manufactured after the flowable material has hardened ( RU 138426 U1, published 20.03.2014 ).
The aforementioned types of formwork are unsuitable for casting concrete underwater due to considerable difficulties involved in their assembly and dismantling in water, or due to rapid deterioration of the formwork material in salt water; furthermore, known formworks are not suitable for casting concrete into wet (flooded) formwork and require the water to be drained from the mould beforehand - using cofferdams, caissons, temporary dams and other costly methods. Furthermore, known formwork systems are unsuitable for pouring concrete under pressure from the bottom upwards and for forming complex three-dimensional structures, such as, for example, stepped retaining walls or zigzag "floor-wall-floor-wall" structures.
Most of the known mass-produced formwork systems for "wall"-type structures are not designed to be moved in their assembled state and require on-site assembly of components. Such formwork systems are generally unsuitable for assembly on the shore, followed by the installation of the fully assembled concrete formwork into the water. Assembling formwork underwater is, however, extremely costly and dangerous. The vast majority of such formwork cannot be easily removed from a concrete structure that has set underwater, and is therefore left underwater, causing significant environmental damage.

Disclosure of the invention.

One of the technical problems solved by the proposed invention is the creation of a "wall"-type retainer, which is the optimal structure in terms of strength-to-material-consumption and strength-to-costs ratios for underwater parts of coastal protection hydraulic structures, for example, jetties, quay walls, embankments, dykes, wet garages or transport infrastructure.
To solve this problem, unlike known permanent formwork systems that use wall panels, the proposed system uses a stack of horizontally laid pipes fixed in a frame (in frames).
The technical result achieved by the patented system lies in the ability to construct wall structures of complex shapes for coastal (in the tidal zone) and/or underwater structures, whilst ensuring the strength and rigidity of the entire structure, as well as the stability of the walls in vertical position.
The proposed technical result is achieved by means of a permanent formwork system for creating concrete retaining wall structures underwater and in the tidal zone, comprising a stack of horizontally laid pipes held together by frame elements, whereby some pipes of the stack or all pipes of the stack are connected to a manifold, representing a pipe section with sockets arranged in a row at fixed intervals for connecting the pipes of the stack, and the frame consists of column-pipes and connecting unit elements, wherein the connecting unit elements are designed as hollow three-dimensional bodies with sockets oriented at angles to one another, some of which are blind-ended, whilst others have pipes arranged therein.
In a particular embodiment of the invention, the frames may be assembled into a structure by connecting them to each other via beam-pipes arranged in the sockets of the connecting unit elements.
In a particular embodiment of the invention, the formwork includes external rods made of metal or composite bars, installed in the openings of the connecting unit elements at an angle to the pipes.
In a particular embodiment of the invention, at least one socket of a connecting unit element is designed to allow connection to a concrete pump for partial or complete filling of the formwork with concrete.
In a particular embodiment of the invention, the connecting unit elements are made of polyethylene or PVC, or polypropylene, or metal, or fiberglass.
In a particular embodiment of the invention, as the pipes are used standard water, gas or sewer pipes.
In a particular embodiment of the invention, the pipes are made of polyethylene, PVC, polypropylene, metal or fiberglass.
In a particular embodiment of the invention, the pipes are secured in the sockets of a connecting unit element by welding or lock joint, or gluing, or socket joint, or fastening with self-tapping screws, anchors, or rivets.
In a particular embodiment of the invention, at least one pipe of the stack is provided with a window in its wall and extends through the manifold in a single piece, whilst retaining the possibility of filling it with concrete.
In a particular embodiment of the invention, the sockets of the connecting unit elements are arranged coaxially, allowing for a through-placement of frame pipes with or without a window.
In a particular embodiment of the invention, the sockets of the connecting unit elements are arranged coaxially to allow a through-placement of rods.
In a particular embodiment of the invention, the pipes are secured in sockets of a manifold by welding or lock joint, or gluing, or socket joint, or fastening with self-tapping screws, anchors, or rivets. They also extend straight through two coaxial manifold sockets.
In a particular embodiment of the invention, one of the manifold sockets is designed to allow connection to a concrete pump.
In a particular embodiment of the invention, the manifold comprises 1-4 rows of units for connecting pipes from stacks.
In a particular embodiment of the invention, some of the manifold sockets are blind-ended.
In a particular embodiment of the invention, the manifold represents one of the frame columns.
In a particular embodiment of the invention, the manifold is formed as a single piece with a connecting unit element.

Description of the drawings.

The solution is further explained with reference to the figures and three-dimensional models, which show the following:

Fig. 1 - general view of the frame.
Fig. 2 - general view of the manifold.
Fig. 3 - general view of the connecting unit element.
Fig. 4 - general view of the formwork system.
Fig. 5 - terraced waterfront system.
Fig. 6 - marine garage system.
Fig. 7 - connecting unit element G1 for a wet garage.
Fig. 8 - connecting unit element for the frame.
Figs. 9 and 10 - examples of manifolds for different tasks.

3D model 1 - formwork system.
3D model 2 - frame.
3D model 3 - connecting unit element.
3D model 4 - manifold.
3D model 5 - terraced waterfront system.
3D model 6 - marine garage system.
3D model 7 - connecting unit element G1 for a marine garage.
3D model 8 - connecting unit element for the frame.
3D models 9 and 10 - examples of manifolds for different tasks.

Implementation of the invention.

A permanent formwork system for creating concrete retaining wall structures underwater and in a tidal zone comprises a stack 1 of horizontally laid pipes held together by frame elements.
The frame consists of column-pipes 2, connecting unit elements 3 and beam-pipes 4 in the case of use of frame structures. Also used may be an arrangement of frames at a specified interval without them being fastened together. The connecting unit elements are designed as hollow three-dimensional bodies with sockets 8 oriented at angles to each other, a part of which is blind-ended, whilst in others are arranged beam-pipes 4 and column-pipes 2. Furthermore, in a particular embodiment, the formwork frame may include external rods 5 made of metal or composite bars, installed in the holes of the connecting unit elements at an angle to the column-pipes and beam-pipes. The column-pipes 2 are used in the assembly of the frame and are standard plastic, composite or metal pipes.
Connecting unit elements 3 allow the frame to be formed from beam-pipes and the ends of the aforementioned column-pipes to be secured. The method of connecting beam-pipes and column-pipes to a connecting unit element may be by socket, coupling, gluing, welding, flange, thread or other means. The distance between the column-pipes and their relative positioning allows a secure fixation within the above described frame of straight or curved stack of pipes.
The stack of pipes is fixated by several separate frames assembled at some intervals or by a single frame structure comprising several frames interconnected by pipe beams - to impart greater strength and rigidity to the entire structure and to ensure stability of the wall in vertical working position.
The connecting unit elements of the frames have a joint for connection to a concrete conduit, which is a flange or a groovelock or a camlock, for monolithic concreting of the frame.
In different embodiments of the invention, the frames and the pipe stacks may be concreted either together or separately. In the latter case, concreted first is the frame structure or individual frames, which have a relatively small internal concreting volume, and after they have gained strength, the pipe stack itself is concreted.
The connecting unit element may have connections for several columns, forming two, three or more separate frames, which allows to create angles, tees or cross-joints in retaining wall structures. Angles, tees or cross-joints are formed by aligning pipe stacks along a common edge or corner.
The sockets of the connecting unit elements are initially carried out blind-ended, wherein for assembly holes are drilled in the required sockets using a hole saw or router bit, allowing the connecting unit element to be adapted to different positions within the frame structure or different types of pipe stacks - depending on the thickness of the pipes in the stack or the bend angle of the stack when forming a retaining wall of a complex shape.
A part of the stack pipes is connected to a manifold 6, which is a pipe section with sockets 7 for connecting the pipes of the stack 1, arranged at equal intervals.
The manifold ensures the formation of a single internal pipe volume, necessary for the simultaneous concreting of the entire stack, and can off also cap or butt the ends of the pipe joints. In certain particular embodiments of the invention, the manifolds may be formed as a single unit with the connecting unit element.
A preset arrangement interval of the manifold sockets ensures that either all pipes in the stack are secured, or that they are secured alternately, for example, every other one. In the latter case, one part is secured to the manifold on one side, and the other part on the other side.
The stack pipes may be connected to the manifold, and the manifold, in turn, to the concrete conduit by means of welding or a lock joint, or gluing, or a socket joint, or by fixing with self-tapping screws, anchors, or rivets.
The manifold may contain one, two, three or four rows of sockets for attaching the stack pipes, which allows for the assembly of angles (bends), tees or cross-joints from the pipe stacks. The sockets also allow for the pipe stack to be capped off and are used in the terminal (end) manifold. Through (coaxial) sockets in the manifold allow pipe joints to be extended.
The manifold may replace one of the column-pipes in the frame or be positioned outside the frame. Examples of manifolds for various tasks are shown in Figs. 2, 9 and 10, as well as in 3D models 9 and 10.

Examples of implementation of the invention.

Example 1.

"Marine wall" structures implemented using concrete fixing frames, manifolds and stacks of horizontal pipes laid one above the other or vertical HDPE pipes (see Fig. 4, 3D model 1). The pipe stacks are joined by reinforcement and filled with concrete via manifolds, or the pipes are combined to form a marine fence. Thus, the structure consists of connecting unit elements with fixings for frames, manifolds and standard HDPE pipes forming the stack, frame columns and truss beams.
For flexible stacks, preferred are pipes with a diameter of 75-90 mm and columns with a diameter of 125 mm. For straight (rigid) stacks, preferred are pipes with a diameter of 125 mm and columns with a diameter of 160 mm.
Such wall structures are used primarily for terrace-style coastal protection, construction of jetties, breakwaters and piers from marine gabions, as well as wet slips.
The main advantages of this series of wall structures are the low weight of the empty formwork; the possibility to assemble relatively large monolithic structures; the "permeability" of the walls to water - which is important for a quick alignment of the groundwater level.

Example 2.

The terraced coastal system DUNE U45, designed for reinforcing embankments or natural shorelines with a slope of 45°-35°. It is also intended for use in seawater. The DUNE system is configured to allow the creation of both horizontal double frames (for vertical driven piles with a diameter of 140 mm) as well as vertical double frames (for stacks of HDPE pipes of 125 mm). It is also for orthogonal double frames to form two composite grids 400 mm apart for the forming marine gabions. It can be used with retaining wall height intervals of 100% or 50%, or with mixed intervals, as well as with frame side ratios of 1:1 or 1:2. It is possible to concrete the frame and pipe stacks separately (when using manifolds). Compatible with M12 and M13 manifolds. Concreting is carried out via GL4.5" flanges.
Terraces can be straight (steps), zigzag or mixed.
The shape of the terraces allows for a reduction in the number of fittings, pipes, or a reduction in the volume of rubble and pebbles to be replaced by replicating the natural water line. Realization of an architectural idea or adjustment of the shape of an artificial dune.
It is possible to create "gabion" tiers at retaining walls.

Example 3.

A particular example of a terraced seafront. Using the described formwork for creating a beach pier for accommodating sunbeds (Fig. 5, 3D model 5) in the tidal zone, allowing holidaymakers to sit at different heights within this area. Arches of pipe stacks retain the sand, creating steps made of sand.
In addition to its resort purpose, such design with arched structures made from pipe stacks creates a beautiful wave effect resembling fish scales during high tide in the coastal zone, which also has a positive impact on the recreational qualities of the structure produced using the described formwork.

Example 4.

A marine garage (see Fig. 6, 3D model 6). The described invention may be used during construction of marine garages (single, double and collective), situated at a distance from the water's edge or embedded into a reinforced shore, seafront.
The garage may be embedded, in which case the gates are installed flush with the reinforced shore. The garage may also be partially embedded, wherein part of the garage walls and the gates project significantly beyond the reinforced shore. The system consists of connecting unit elements G1 (see Fig. 7, 3D model 7), triple T-manifolds M13 and straight manifolds M12 (see Fig. 3, 3D model 4). The system contains everything necessary to create the underwater section of the structures and the tidal zone.
The wet garage does not have, by default, a continuous "watertight" floor, as it will be flooded to some extent during storms.
The above-water section and garage doors are designed, purchased and installed separately. The use of vertical columns and bracing provided for in the connecting unit element G1 is optional.

Claims

A permanent formwork system for creating concrete retaining wall structures underwater and in tidal zones, comprising a frame in which a stack of pipes is fixed, wherein the frame consists of columns and connecting unit elements, the connecting unit elements of the frame being implemented as hollow three-dimensional bodies with pipes oriented at angles to one another, a part of which are blind-ended, whilst others have columns installed in them, and the manifold is a pipe section with sockets arranged at equal intervals, to which some or all of the stack pipes are connected, wherein the manifold is formed as a single unit with one of the frame's unit elements or one of the columns is formed as a manifold.
The system according to claim 1, wherein in the holes of the connecting unit elements at an angle to the columns and/or the stack pipes are installed external rods made of metal or composite bars.
The system according to claim 1, wherein at least one socket of the connecting unit element is configured to allow connection to a concrete pump for filling the formwork with concrete.
The system according to claim 1, wherein the connecting unit elements are made of polyethylene or PVC, or polypropylene, or metal, or fiberglass.
The system according to claim 1, wherein as stack pipes, as columns and as pipe beams are used standard water pipes, gas pipes or sewer pipes.
The system according to claim 1, wherein the stack pipes, columns and pipe beams are made of polyethylene, PVC, polypropylene, metal or fiberglass.
The system according to claim 1, wherein the columns and pipe beams are secured in the sockets of the connecting unit element by welding or lock joint, or gluing, or socket joint, or fastening with self-tapping screws, anchors, or rivets.
The system according to claim 1, wherein at least one of the stack pipes, columns and/or pipe beams is provided with a window in its wall.
The system according to claim 2, wherein the sockets of the connecting unit elements are arranged coaxially to allow for a through-placement of rods.
The system according to claim 1, wherein the stack pipes are secured in the manifold sockets by welding or lock joint, or gluing bonding, or socket joint, or with self-tapping screws, anchors, or rivets.
The system according to claim 1, wherein one of the manifold sockets is configured to be connected to a concrete conduit by welding, lock joint, or gluing, or socket joint, or fastening with a clamp, or with self-tapping screws, anchors, or rivets.
The system according to claim 1, wherein the manifold comprises 1-4 rows of sockets for connecting the stack pipes.
The system according to claim 1, wherein a part of the manifold sockets are blind-ended.