GB2556915A

GB2556915A - Apparatus, system and method for use in displacement boring for forming a pile

Info

Publication number: GB2556915A
Application number: GB1619970.5A
Authority: GB
Inventors: Hibbert Chris
Original assignee: Roger Bullivant Ltd
Current assignee: Roger Bullivant Ltd
Priority date: 2016-11-25
Filing date: 2016-11-25
Publication date: 2018-06-13
Anticipated expiration: 2036-11-25
Also published as: GB2556915B; GB201619970D0

Abstract

A modular displacement bore tool-head 201 for use in displacement boring for forming a pile comprising a module 202 releasably attachable to another module of the tool-head and featuring a displacement body that defines a displacement profile and means 301a/301b for receiving or transmitting torque from or to another module. The displacement profile may be a helical flight 202 and the module may be connectable to a lead taper 204 and a drive coupling 203. An aperture may pass through the module to allow cement to flow through the module. The modular construction allows individual modules to be interchanged.

Description

(54) Title of the Invention: Apparatus, system and method for use in displacement boring for forming a pile Abstract Title: Modular displacement bore head (57) A modular displacement bore tool-head 201 for use in displacement boring for forming a pile comprising a module 202 releasably attachable to another module of the tool-head and featuring a displacement body that defines a displacement profile and means 301a/301b for receiving or transmitting torque from or to another module. The displacement profile may be a helical flight 202” and the module may be connectable to a lead taper 204 and a drive coupling 203. An aperture may pass through the module to allow cement to flow through the module. The modular construction allows individual modules to be interchanged.

02 17

02 17

FIG. 4

02 17

02 17

Create bore using module/moduiar displacement bore tool-head

Introduce settable material Into bore

APPARATUS, SYSTEM AND METHOD FOR USE IN DISPLACEMENT BORING FOR FORMING A PILE

TECHNOLOGICAL FIELD

Examples of the present disclosure relate to an apparatus, system and method for use in displacement boring for forming a pile. Some examples, though without prejudice to the foregoing, relate to a modular displacement bore tool-head, and one or more modules for the same, configured for use in creating a bore via displacement for the formation of a pile.

BACKGROUND

There are various techniques for forming piles in the ground for use in supporting buildings or other structures. Preformed piles may be driven into the ground by hammering or vibration. Alternatively, piles may be formed in situ by introducing a settable material into a bore/cavity formed in the ground. Various boring techniques have been proposed for forming such a bore. Full Displacement Piling (FDP) is one such technique in which a tool head, referred to as a “bullet”, is driven and rotated into the ground via lengths of drive pole which are connected to a high torque gearbox mounted on, and guided by a rig mast. Such a single piece/unitary displacement bore tool-head is configured so that when rotatably driven into the ground, the tool head forces the ground radially around the tool-head thereby laterally displacing the ground to create a void cavity/bore. Advantageously, instead of requiring the extraction and removal of large amounts of material from the ground in the formation of the bore, the displacement bore tool-head causes the ground material to be displaced and compressed in the vicinity of the displacement bore tool-head.

Once the bore has been made to the desired depth, as the displacement bore tool-head is withdrawn from the bore, concrete is carefully pumped into the bore under pressure through the tool head. The concrete sets, in-situ, to form a pile. Such full displacement boring techniques (and also partial displacement boring techniques) may enable an improvement to the surrounding ground, due to such displacement and compression which may enable the formation of pile with a higher pile load tolerance or may enable the use of a shorter pile (and thus reduced amount of concrete) as compared to a bore in which the material of the bore is excavated and removed. Since shorter piles may be used with reduced amounts of concrete or other settable material required, the production rate of pile formation may be increased. Also, since displacement boring techniques minimise the amount of ground material excavated, they are particularly useful for contaminated ground.

Due to significant forces that a displacement boring tool-head undergoes during use, the displacement bore tool-head may well become damaged/deformed and require repair. Any deformations to the displacement bore tool-head may alter the dimensions and displacement profile of the displacement bore tool-head. This affects the dimensions and shape of the bore which also affects the volume, pressure and rate of the pumping of the concrete into the bore. Thus, to accurately and appropriately adjust the control of the pumping of the concrete, an accurate knowledge of the dimensions and displacement profile of the displacement bore tool-head is required. Thus deformations to the displacement bore toolhead create difficulties in the correct/appropriate control of the pumping of the concrete.

Furthermore, repair work carried out on the displacement bore tool-head, such as applying hard facing welds to the exterior surface of the displacement bore tool-head may likewise alter its dimensions and displacement profile. In order to increase the durability of the tool head, and reduce the severity of deformations and amount of repair work required during use, typically a high wearing and high cost material would be required to create a sufficiently durable displacement bore tool-head. Not only are the raw materials for such tool-heads expensive, but also such tool heads would have high manufacturing costs as the tool head casting/fabricating/creating process itself may well be expensive.

Conventional displacement bore tool-heads for displacement boring for forming a pile are not always optimal. Certain examples of the present disclosure seek to provide an improved displacement bore tool-head.

The inventor of the present application has sought to provide an improved displacement bore tool-head in which the displacement bore tool-head itself is provided as a modular unit having different modules/sections that can be readily interchanged (as compared to the displacement bore tool-head itself being a single integral/unitary unit). Advantageously, instead of creating an integral single piece displacement bore tool-head/bullet (which may be made of an expensive high-wearing material to seek to minimise repair following wear and tear of the tool-head) a modular tool-head is provided in which particular sections thereof may be readily interchanged and replaced on site, rather than needing an entire tool-head to be sent off for repair.

The listing or discussion of any prior-published document or any background in this specification should not necessarily be taken as an acknowledgement that the document or background is part of the state of the art oris common general knowledge. One or more aspects/examples of the present disclosure may or may not address one or more of the background issues.

BRIEF SUMMARY

According to at least some examples of the disclosure there is provided a module of a modular displacement bore tool-head, the modular displacement bore tool-head being configured for use in displacement boring for forming a pile, wherein the module is configured to be releasably attachable to another module of the modular displacement bore tool-head, the module comprising:

a displacement body that defines a displacement profile of the modular displacement bore tool-head; and means for receiving/transmitting torque from/to the another module of the modular displacement bore tool-head.

According to at least some examples of the disclosure there is provided a drive coupling interconnector module of a modular displacement bore toolhead, the modular displacement bore tool-head configured for use in displacement boring, wherein the drive coupling interconnector module is configured to be releasably attachable to another module of the modular displacement bore tool-head, the drive coupling interconnector module comprising:

a first drive coupling configured to engage with and receive torque from a drive coupling of a drive shaft; and a second drive coupling configured to engage with and transmit torque to a drive coupling of the another module.

According to at least some examples of the disclosure there is provided an end module of a modular displacement bore tool-head, the modular displacement bore tool-head being configured for use in displacement boring, wherein the end module is configured to be releasably attachable to another module of the modular displacement bore tool-head, the end module comprising:

a first drive coupling configured to engage with and receive torque from a drive coupling of the another module.

According to at least some examples of the disclosure there is provided a modular displacement bore tool-head comprising one or more of the above mentioned modules.

According to at least some examples of the disclosure there is provided a method of forming a pile comprising: creating a bore using one or more of the above mentioned modules.

According to at least some examples of the disclosure there is provided a pile formed by the above mentioned method.

BRIEF DESCRIPTION OFTHE DRAWINGS

For a better understanding of various examples of the present disclosure that are useful for understanding the detailed description and certain embodiments of the invention, reference will now be made by way of example only to the accompanying drawings in which:

Figure 1 schematically illustrates an apparatus;

Figure 2 shows a modular displacement bore tool-head;

Figure 3 shows an exploded view of the modular displacement bore tool-head of Figure 2;

Figure 4 shows a means for receiving/transmitting torque from/to one module of the modular displacement bore tool-head;

Figures 5A and 5B show a side on view and a side on cross-sectional cut through view of a modular displacement bore tool-head;

Figures 6A to 6C schematically illustrate use of a modular displacement bore tool-head in the formation of a pile; and

Figure 7 schematically illustrates a method for forming a pile.

The Figures are not necessarily to scale. Certain features and views of the figures may be shown schematically or exaggerated in scale in the interest of clarity and conciseness. For example, the dimensions of some elements in the figures may be exaggerated relative to other elements to aid explication. Similar reference numerals are used in the Figures to designate similar features. For clarity, all reference numerals are not necessarily displayed in all figures.

DETAILED DESCRIPTION

The Figures schematically illustrate a module (102) of a modular displacement bore tool-head (101), the modular displacement bore tool-head (101) being configured for use in displacement boring for forming a pile, wherein the module (102) is configured to be releasably attachable to another module (103, 104) of the modular displacement bore tool-head (101), the module (102) comprising:

a displacement body (102’) that defines a displacement profile (610) of the modular displacement bore tool-head (101);

means (301) for receiving/transmitting torque from/to another module (103, 104) of the modular displacement bore tool-head (101).

For the purposes of illustration and not limitation, an advantage/technical effect of some examples of the present disclosure may be to provide a modular displacement bore tool-head, and modules for the same, that enable the inter-changeability of an individual module of the tool-head without replacing the entirety of the whole of the tool-head.

For example, the modular displacement bore tool-head (101) comprises: an end module which penetrates into the ground, a displacement module/midsection that defines the displacement profile of the displacement bore toolhead, and a drive coupling interconnector module of the modular displacement bore tool-head. As will be readily appreciated, the term module in the context of a modular displacement bore tool-head pertains to one of a set of separate parts of the tool head that, when combined, form the complete tool head.

If the displacement module/mid section were to be damaged/deformed during use, this individual modular section could be removed and replaced without requiring the replacement of the entirety of the tool-head, i.e. the end module and drive coupling module could be re-used with a new displacement module. Likewise, a displacement module could be selected from several differing displacement modules having differing dimensions and displacement profiles so that an optimal displacement module may be used for a particular application/ground type, i.e. such that the displacement module is appropriately sized and dimensioned for the desired bore/pile to be formed. A substantially cylindrical displacement module could be provided whose displacement profile is such that, in use, a bore of a substantially cylindrical cross-sectional profile is created. Alternatively, a displacement module could be provided, having a helical flight on its exterior surface such that, in use (having been rotatably driven into the ground and rotatably withdrawn therefrom), a bore could be created having a central circular column along with a helical profile along its length.

Furthermore, should the modular displacement bore tool-head need to be attached to differing types of drive poles/drive shafts having differing coupling types, a first drive coupling interconnector module configured to couple to a first type of drive coupling could be exchanged with a second drive coupling interconnector module configured to couple to a second type of drive coupling. Thus, the modular displacement bore tool-head can readily be re-configured/adapted so as to be compatible with to a particular drive coupling/driving machine, via replacement of just the drive coupling interconnector module, without having to replace the entirety of the tool head.

Yet furthermore, the end module of the modular displacement bore toolhead may be readily replaced and interchanged. The end module may typically comprise removable cutting teeth which are detachably connected to tooth-holders that are fixedly attached to the end module. In prior single piece/unitary displacement bore tool-heads, if the tooth-holders were to get damaged, then the entire tool-head would need to be removed and repaired. By contrast, in examples of the present disclosure, by providing a removable end module, only the end section need be removed and replaced.

Examples of the present disclosure, providing a modular displacement bore tool-head, wherein modules thereof are removably detachable to one another, thereby enabling removal and replacement of an individual module (rather than replacement of the entirety of the tool head). Advantageously, this minimises disruption to the boring and pile forming process.

Examples of the present disclosure may increase the flexibility of the displacement bore tool-head, by enabling the selection of individual modules suitable and optimised for a particular application and may enable rapid inter-changeability of the module, on site. Thus time and transportation costs (for transporting entire tools to and from a site for repair) are reduced. Furthermore, since worn/damaged modules may be rapidly removed and replaced on site, individual modules may be manufactured from a material of a lower durability than may otherwise be required since a modular portion may be readily changed rather than needing to be made of an expensive durable material that does not require replacement as frequently.

Figure 1 focuses on the functional components necessary for describing the operation of the apparatus.

Figure 1 shows an example of an apparatus 100 for creating a bore for forming a pile via a displacement technique. The apparatus comprises a displacement bore tool-head 101 which is configured so as to be modular. The displacement bore tool-head is the operational part of the apparatus that effects the core functionality of the displacement boring process, i.e. it is the operational tool end part of the apparatus that penetrates the ground and effects the displacement of the ground.

The modular displacement bore tool-head 101 comprises an intermediate module 102 that is configured to be releasably attachable at one end thereof to another module of the modular displacement bore tool-head, such as a drive coupling interconnector module 103. The other end of the module 102 is configured to be releasably attachable to another module of the modular displacement bore tool-head, such as an end module 104. The intermediate module 102 comprises a displacement body 102’ that comprises the greatest cross sectional extent of the modular displacement bore toolhead 101, and thus substantially effects the displacement of the ground upon being driven into the same and defines the dimensions of the resultant bore. Since the intermediate module 102 substantially effects the displacement functionality, it is referred to as the displacement module 102 of the modular displacement bore tool-head 101.

The displacement module 102 also comprises means (not shown in Figure 1, but shown with reference to 301a, 301b and 301 in Figures 3 and 4) for receiving/transmitting torque from/to another module of the modular displacement bore tool-head 101. A first end of the module 102 comprises means for receiving torque from the drive coupling interconnector module 103. At the other end, the displacement module 102 comprises means for transmitting torque to the end module 104.

In the modular displacement bore tool-head 101 shown in Figure 1, the modular displacement bore tool-head comprises three modules, namely the drive coupling interconnector module 103, the displacement module 102 and the end module 104, wherein the end module 104 and the drive coupling interconnector module 103 are both releasably attachable to the intermediate module 102. However, in other examples, the modular displacement bore-tool head 101 may have just two modules. For example, the end module and the displacement module may be provided as a single integral module that is releasably attachable to the drive coupling interconnector module 103.

The modular displacement bore tool-head 101 is coupled to a drive shaft 105 (shown in outline). It is to be appreciated that the drive shaft itself is not a part of the modular displacement bore tool-head. The modular displacement bore tool-head is coupled to the drive shaft 105 via the drive coupling interconnector module 103. The drive shaft 105 is itself rotatably driven via suitable means, such as a motor or gearbox mounted on and guided by a rig mast. In use, the modular displacement bore tool-head 101 is driven into the ground by the gearbox using the dead weight of the gearbox and the drive shaft/drive pole as well as the weight of the modular displacement bore tool-head itself, i.e. the driving force is the weight of the apparatus itself.

In the example shown in Figurel, the displacement body 102’ of the displacement module 102 has a substantially cylindrical shape such that a bore created via such a displacement module would have a substantially cylindrical profile, i.e. a circular cross-sectional shape with dimensions equivalent to the cross-sectional dimensions of the displacement body. In other examples, the displacement body 102 may additionally comprise one or more protrusions 202” such as is shown in the modular displacement bore tool-head 201 of Figure 2. Such protrusions may define a flight or auger to such that the modular displacement bore tool-head 201 provides a modular auger displacement tool-head.

The modular displacement bore tool-head 201 shown in Figure 2 has a displacement module 202 which comprises a displacement body 202’ that additionally comprises a protrusion 202” in the form of one or more helical flights that protrude from the cylindrical part of the displacement module 202. The protrusion 202” from the exterior surface of the protrusion body thereby alter the displacement module’s displacement profile, such that the displacement profile is defined having a cylindrical portion with the addition of a helical profile along its length (as schematically illustrated in Figure 6B with reference to displacement profile 610).

The modular displacement bore tool-head 201 in Figure 2 may be used to provide Continuous Helical Displacement (CHD) which is a type of rotary Full Displacement Piling (FDP) technique developed by Roger Bullivant Ltd. Whereas other FDP techniques may create a bore having a simple cylindrical profile, the CHD process not only creates a bore having a central circular column, but additionally creates a wide helical profile along the entire length of the bore due to provision of a wide helical flight of the CHD displacement bore tool-head which is driven and rotated into the ground and counter rotated upon extracting the tool from the ground. Thus, the modular displacement bore tool-head 201 of Figure 2 may provide a modular CHD tool head.

The modular CHD tool-head may comprise a displacement module 202 comprising a fabricated tube/cylinder, for example having a diameter of 200mm, 300m or, 400mm (though it is clearly to be appreciated that other sizes of diameter could be provided). The end module 204 comprises a conical section that is releasably attached to the displacement module 202. The displacement body 202’ of the displacement module 202 comprises a helical flight 202” (which may be, for example, parallel or trapezoidal) of a defined pitch, for example, 200mm, 250mm and 300mm (again it is to be appreciated that other pitch sizes may be used). The helical flight may be welded to the central tube portion of the displacement module 202.

The displacement module 202 also comprises a small diameter pipe, for example 100mm or 125mm, which may be welded along the entire length of the displacement module 202 so as to allow the passage of settable material, such as concrete, therethrough.

In use, the modular displacement bore tool-head 201 is rotated into the ground by a high torque gearbox until it reaches a predetermined design depth. Once the desired depth has been achieved, the modular displacement bore tool-head 201 is lifted slightly and settable material, such as concrete, is pumped under pressure through the modular displacement bore tool-head 201 to fill created bore with settable material whilst the modular displacement bore tool-head 201 is counter-rotated and extracted through the created displaced bore. The tool-head is extracted by rotation in the opposite direction to that of the insertion rotation direction. The tool is lifted during rotation so as to follow, as near as possible, the flight pitch created during the insertion of the tool to create the displacement bore. This process may be done manually, using instrumentation to guide the operator or can be fully automated. The settable material introduced into the bore sets in situ thereby forming a pile.

Instrumentation used in controlling the extraction of the tool-head and pressure, volume and rate of concrete pumped into the created bore are typically configured for use with Continuous Flight Auger (CFA) boring techniques. CFA is a non-displacement boring technique in which a circular column bore of a particular constant diameter and depth is created via a Continuous Flight Auger (i.e. an auger that extends along the length of the bore) that removes and extracts ground in the creation of a bore hole (as compared to displacement boring techniques which creates a bore via displacing and compressing the ground out of the way of the displacement bore tool-head as it is inserted into the ground). For instrumentation configured for CFA techniques, to work for CHD techniques, i.e. in which the bore is not a simple cylindrical shape but further has a helical profile along its length, it is necessary to calculate an ‘equivalent CFA diameter' that will be used for a particular CHD tool. The equivalent CFA diameter is a function of the shaft diameter plus the material displaced by the flight of the CHD tool head for every metre of pile.

Previous CHD tool-heads were fabricated as a single integral unit in which a mid-section displacement body, comprising a helical flight, had a conical section welded to each end thereof. On one of the conical sections, a drive coupling is welded for interconnection with a drive shaft, whilst one or more cutting teeth are welded on the other conical section. In order to increase the lifetime of the tool, additional hard-facing welds would routinely be applied to the surface ot the flight. This would change the profile ot the flight and thus alter the equivalent CFA diameter for the tool head. Furthermore, such previous integral single CHD tool-heads, referred to as CHD bullets, typically had to be regularly returned for repair. The repair work would again affect the profile and pitch of the helical flight and thus the equivalent CFA diameter. The variability in dimensions of the tool and in particular the flight of the tool provides a large variability in the equivalent CFA diameters that are used in controlling the pumping of concrete during the extraction of CHD bullets and forming of a pile thereby.

For previous CHD bullets, in order to seek to determine accurate equivalent CFA diameters, operators had to measure the CHD bullet regularly and use look-up tools to determine the equivalent CFA diameter to be used with their instrumentation. The modular displacement bore tool-head of the present disclosure enables the use of displacement modules/mid-sections that can be readily interchanged so that when worn/damaged (i.e. such that the displacement profile of the displacement module is significantly altered), the displacement module can be readily replaced with a new displacement module thereby ensuring that a consistent displacement profile may be used.

Furthermore, the modular approach to a displacement bore tool-head enables the displacement module to be readily swapped to another displacement module having a particular displacement profile for creating a bore of a particular desired profile to form a pile of a particular design.

Furthermore, the modular approach to a displacement bore tool-head enables the drive coupling interconnector module to be readily swapped to another drive coupling interconnector module having a particular drive coupling for coupling to a particular rotary driving machine.

Furthermore, the modular approach to a displacement bore tool-head enables the use of a releasably attachable end module, such as a removable lead taper. This may save significant time and money as this part of the tool-head may have removable cutting teeth which are attached to welded on tooth-holders. If the tooth-holders were to get damaged, the toolhead cannot be used in previous CHD bullets (wherein the lead taper was integrally formed/welded on to the intermediate displacement section). Previously, for such CHD bullets, where the tooth-holders became damaged during use, the entire CHD bullet would need to be sent back to the workshop for repair. Examples of the present disclosure provide removable lead taper modules which may enable just the lead taper module to be removed and replaced on site with another lead taper module.

The various modules 202, 203, 204 of the modular displacement bore toolhead 201 may be made of any suitable materials. In some examples, the modules are made from ductile iron. The end module may comprise teeth that could be incorporated as part of the casting.

Benefits of examples of the present disclosure may include: ability to interchange the modules of the modular displacement bore tool-head on site to allow for rapid changes in tool choice in response to design changes, reduced costs in transporting tools to and from the site for repair, and rapid onsite changing of worn parts. This can give rise to cost savings in terms of significantly reduced tool repair time. Furthermore, displacement modules having consistent flight pitches and profile may be provided which are simply replaced with a fresh/new displacement module when a used displacement module is worn, thereby ensuring the consistent flight pitch and displacement profile. This may enable better control of the control instrumentation for the boring and pumping of the concrete into the pile.

Figure 3 is an exploded view of the modular displacement bore tool-head 201 of Figure 2. The modular displacement bore tool-head, herein after referred to as CHD tool, comprises: a displacement module 202, herein after referred to as a mid-section, a drive coupling interconnector module 203 herein after referred to a s a drive coupling, end module section 204, herein referred to a s lead taper. The mid-section 202 may comprise a generally tubular structure 202'. It is fabricated with a welded on solid pressed flight 202 or cast including the flight. The mid-section 202 may be created in a variety of sizes. Each end of the mid-section 202 is provided with means for receiving/transmitting torque from/to the other module. Such means may correspond to a dog drive 301a, 301b provided at each end of the midsection 202. The dog drive 301a, 301 b allows for the transmission of gearbox torque via the drive coupling 203, which interconnects the CHD tool 201 with a drive pole/drive shaft (not shown in, but shown with reference to 105 in Figure 1). The drive coupling 203 comprises a dog drive 302 which interconnects and inter-mates/inter-engages with the dog drive 301a of the midsection 202 so that torque is conveyed to the mid-section. The dog drives 301a, 301 b at each end of the mid-section 202 are securely fixed to the midsection such that the transmitted torque is conveyed from one end of the mid-section, through the tubular member of the mid-section, to the other end of the mid-section and the dog drive 301b at the other end. The dog drive 301b inter-connects and inter-mates/inter-engages with a dog drive 303 of lead taper 204. The mid-section 202 is mechanically connected to the drive coupling 203, using a set of high tensile bolts 304 which pass through the dog drive 303 of the lead taper 204 and terminate in threaded holes 305 of the dog drive 302 of the drive coupling 203.

The lead taper 204 may comprise one or more: augers, flights, teeth holders and cutting teeth. The lead taper 204 may be made from, not least for example: solid steel, solid cast iron, solid plastic or may be fabricated using integral; proprietary items which are then fitted over the dog drive 303 and secured in place using drive pins 306. Such a method of retraining the lead taper 204 may enable the simple and rapid changing of the lead taper 204 when it is worn, and also provides the additional benefit of protecting the securing bolts 304 from the ingress of dirt and concrete keeping them clean to facilitate rapid onsite interchangeability.

By providing a displacement bore tool-head 201 as a modular structure, individual modules of the tool-head may be readily replaced. Since individual modules may be readily replaced, the modules need not last as long as they would need to if the tool were to comprise a single integral piece and moreover, the modular displacement bore tool-head 201 may be more customisable for future applications not least for example, changing one or more of the end module 204 and displacement module 202 for particular ground types and/or desired bore profile. Furthermore, the drive coupling interconnector module 203 may be replaced so as to provide appropriate interconnection to differing types of drive shafts and draft shaft interconnectors.

The modular displacement bore tool-head 201 (and each of its constituent modules 202, 203 and 204) is provided with a central cavity therethrough for enabling the passage of a settable material therethrough, such as concrete. The hollow central sections of the modules defining central passages for the conveyance of settable material therethrough are shown with reference 308, 309 and 310. At the end of the lead taper 204, a soil cap may be provided (not shown) which covers the lead taper’s aperture 310 during the insertion and rotation of the modular displacement bore tool-head 201 into the ground. During the extraction of the tool-head, pressurised concrete is pumped through the tool-head. Such pressurised concrete displaces the soil cap and fills the bore with concrete during the extraction of the tool-head. In the example in Figure 4, the drive coupling is a dog drive. However, other torque transmitting drive couplings may be used.

Figure 4 shows a view of a drive coupling 301 which may be used, for example, as means for receiving/transmitting torque to/from the displacement module to the other modules of the modular displacement bore tool-head. For example, the drive coupling 301 may correspond to the torque receiving/transmitting means 301a and 301 b in Figure 3.

Figures 5A and 5B show side on views of the CHD tool 201. Figure 5B is a crosssectional cut-through view along the line AA of Figure 5A.

The various modules may be releasably attached to one another via an assembly for releasably attaching/connecting the module, such as via mechanical attachment means, fastening means, fasteners, bolts and drive pins. In various examples of the disclosure, the means for releasably attaching the modules together need not be configured so as to transmit the torque but need only retain the modules together. For example, with regard to Figure 5B, the high-tensile bolts 304 are not used in the transmission of torque but are merely used to retain the modules together in a longitudinal direction. Separate means are provided for receiving and transmitting torque, namely the drive couplings/dog drives 301a and 301b of the intermediate displacement module 202 which interconnect with corresponding respective drive couplings/dog drives of the other modules 203, 204. The mechanical attachment means merely securely fix the module parts together in a longitudinal direction.

The means for receiving/transmitting torque may comprise a first drive coupling 301a configured to engage with a drive coupling 302 of the drive coupling interconnector module 203, the means for receiving/ transmitting torque may comprise a second drive coupling 301b configured to engage with a drive coupling 303 of the end module 204. Such drive couplings may comprise an interlocking mechanism, such as a dog drive/dog clutch that provide an interference fit/engagement/mate for conveying torque between the modules. The drive coupling interconnector module itself may receive torque from a drive shaft/drive pole which is driven by a high-torque gearbox.

The displacement module 202 may comprise a drive coupling at each of its ends, namely drive coupling 301a and 301b, wherein each drive coupling is fixedly secured to the displacement module 202 so that torque is able to be transmitted from one drive coupling to the other via the displacement module 202 itself, in particular the cylindrical housing member of the displacement module. The drive couplings may be fixedly secured by being integrally formed, cast, fabricated or welded on to the cylindrical member of the displacement module.

The modular displacement bore tool-head may be configured to provide at least one or more of:

full displacement boring, partial displacement boring (wherein there is minimal spoiled/excavated ground following the creation of the bore), and continuous helical displacement boring. The drive coupling interconnector module 203 may comprise a first drive coupling 311 configured to engage with and receive torque from a drive coupling of a drive shaft, and a second drive coupling 302 configured to engage with and transmit torque to a drive coupling 301a of the displacement module 202. The end module 204 may comprise a first drive coupling 303 configured to engage with and receive torque from a drive coupling 301 b of the displacement module 202.

Figures 6A, 6B and 6C schematically illustrate the modular displacement bore tool-head 201 in use.

A pile forming apparatus 600 comprises the modular displacement bore toolhead 201, a length of drive shaft 601 and high torque gearbox 602 which drives the drive shaft 601 and modular displacement bore tool-head 201 rotating it into the ground. The cutting implements 307 of the end module 204, in combination with the helical flight 202” of the displacement module 202, are rotatably driven into the ground under the dead weight of the tool itself in combination with the lengths of drive shaft 601 as well as the gearbox 602 supported by rigging (not shown). In some examples, additional means and mechanisms may be provided to drive and further force the modular displacement bore tool-head 201 into the ground.

Figure 6B shows the creation of the bore 610 after the tool-head has been drilled into the ground down to the desired depth causing a displacement of the ground in a radiol/lateral/sideways direction as indicated by arrows 605. The tool-head is extracted by rotating the tool-head in the opposite direction and lifting it out of the hole. During the extraction of the tool-head, settable material, such as concrete, is pumped into the bore under pressure as figuratively shown with arrows 606. The concrete passes through a central aperture/internal passageway 607 of the drive shaft 601, and through the central aperture/internal passageway of modular displacement bore toolhead 201.

Figure 6C shows the tool-head having been completely removed from the bore, and the bore having been completely filled with concrete. The concrete sets in situ thereby forming a pile 611. In the example shown in Figures 6A-6C, the displacement bore tool-head comprises a helical flight 202” so as to provide Continual Helical Displacement bore/pile such that the pile has a generally cylindrical central column with a helical profile along its length.

Figure 7 schematically illustrates a method 700. In box 701, a bore is created using one or more modules of a modular displacement bore tool-head as described above. Settable material, such as concrete, is introduced into the created bore. Such settable material subsequently sets so as to thereby form a pile.

Certain examples of the present disclosure extend to piles formed by such a method and/or via modules of the modular displacement bore tool-head as discussed above.

Features described in the preceding description may be used in combinations other than the combinations explicitly described. Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain examples, those features may also be present in other examples whether described or not. Although various examples of the present disclosure have been described in the preceding paragraphs, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as set out in the claims.

The term ‘comprise’ is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising Y indicates that X may comprise only one Y or may comprise more than one Y. If it is intended to use ‘comprise’ with an exclusive meaning then it will be made clear in the context by referring to “comprising only one ...” or by using “consisting”.

In this description, the wording ‘connect’, ‘couple’ and ‘communication’ and their derivatives mean operationally connected/coupled/in communication. It should be appreciated that any number or combination of intervening components can exist (including no intervening components).

In this description, reference has been made to various examples. The description of features or functions in relation to an example indicates that those features or functions are present in that example. The use of the term ’example’ or ‘for example’ or ‘may’ in the text denotes, whether explicitly stated or not, that such features or functions are present in at least the described example, whether described as an example or not, and that they can be, but are not necessarily, present in some or all other examples. Thus ‘example’, ‘for example’ or ‘may’ refers to a particular instance in a class of examples. A property of the instance can be a property of only that instance or a property of the class or a property of a sub-class of the class that includes some but not all of the instances in the class.

In this description, references to “a/an/the” [feature, element, component, means ...] are to be interpreted as “at least one” [feature, element, component, means ...] unless explicitly stated otherwise.

Whilst endeavouring in the foregoing specification to draw attention to those features of examples of the present disclosure believed to be of particular importance it should be understood that the applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

The examples of the present disclosure and the accompanying claims may be suitably combined in any manner apparent to one of ordinary skill in the art.

Claims

CLAIMS We claim:

1. A module of a modular displacement bore tool-head, the modular displacement bore tool-head being configured for use in displacement boring for forming a pile, wherein the module is configured to be releasably attachable to another module of the modular displacement bore tool-head, the module comprising:

2. The module of claim 1, comprising means for mechanically detachably connecting:

an end module of the modular displacement bore tool-head, and/or a drive coupling interconnector module of the modular displacement bore tool-head.

3. The module of any previous claim, wherein the means for receiving/transmitting torque comprises a first drive coupling configured to engage with a drive coupling of:

an end module of the modular displacement bore tool-head, or a drive coupling interconnector module of the modular displacement bore tool-head.

4. The module of claim 3, wherein the module comprises a second drive coupling configured to engage with a drive coupling of:

a drive coupling interconnector module of the modular displacement bore tool-head, or an end module of the modular displacement bore tool-head.

5. The module of any previous claim, comprising a substantially cylindrical member having a drive coupling at each end, wherein each drive coupling is fixedly secured to the cylindrical member such that torque is able to be transmitted from one drive coupling to the other via the cylindrical member itself.

6. The module of any previous claim, wherein the displacement body comprises a substantially cylindrical member thereby defining a substantially cylindrical displacement profile of the modular displacement bore tool-head for creating, in use, a bore having a substantially cylindrical cross section via displacement.

7. The module of any previous claim, wherein the displacement body comprises at least one external protrusion.

8. The module of claim 7, wherein the at least one external protrusion comprises at least one helical flight thereby defining a displacement profile comprising a helical profile for creating, in use, a bore via displacement having a helical profile alone the bore’s length.

9. The module of any previous claim, wherein the module comprises an aperture therethrough for allowing the passage of a settable material therethrough.

10. The module of any previous claim, wherein the module is manufactured from iron.

11. The module of any previous claim, wherein the modular displacement bore tool-head is configured for at least one of:

full displacement boring, partial displacement boring, and continuous helical displacement boring.

12. A drive coupling interconnector module of a modular displacement bore tool-head, the modular displacement bore tool-head configured for use in displacement boring, wherein the drive coupling interconnector module is configured to be releasably attachable to another module of the modular displacement bore tool-head, the drive coupling interconnector module comprising:

13. The drive coupling interconnector module of claim 12, further comprising an aperture therethrough for allowing the passage of a settable material therethrough.

14. An end module of a modular displacement bore tool-head, the modular displacement bore tool-head being configured for use in displacement boring, wherein the end module is configured to be releasably attachable to another module of the modular displacement bore tool-head, the end module comprising:

15. The end module of claim 14, further comprising one or more of: a substantially frustro-conical shaped member / lead taper, an auger, one or more cutting teeth, one or more cutting teeth holders, and an end cap to cover an aperture of the end module.

16. A method of forming a pile comprising: creating a bore using one or more of:

the module of previous claims 1 to 8, and 15 the modular displacement bore tool-head of claims 9-14; and

1” introducing settable material into the bore.

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Intellectual

Property

Office

Application No: GB 1619970.5 Examiner: Dr Louis Emery

16. The end module of claims 14 or 15, wherein the end module comprises an aperture therethrough for allowing the passage of a settable material therethrough.

17. A modular displacement bore tool-head comprising one or more of: the module of previous claims 1 to 11, the drive coupling interconnector module of claims 12 - 13, and the end module of claims 14 - 16.

18. The modular displacement bore tool-head of claim 17, wherein the modular displacement bore tool-head is configured such that, in use when rotatably driven into the ground, the modular displacement bore tool-head laterally displaces the ground to form a bore.

19. An apparatus for forming a pile comprising one or more of: the module of previous claims 1 to 11, the drive coupling interconnector module of claims 12 - 13, the end module of claims 14 - 16, and the modular displacement bore tool-head of claims 17-18;

20. A method of forming a pile comprising: creating a bore using one or more of:

the module of previous claims 1 to 11, the drive coupling interconnector module of claims 12 - 13, the end module of claims 14 - 16, and the modular displacement bore tool-head of claims 17-18; introducing settable material into the bore.

21. A pile formed by the method of claim 20.

22. A modular displacement bore tool-head or a module for the same substantially as hereinbefore described with reference to and/or as shown in the accompanying drawings.

Amendment to the claims have been filed as follows

We claim:

1209 17

5 1. A module of a modular displacement bore tool-head, the modular displacement bore tool-head being configured for use in continuous helical displacement boring for creating a bore for forming a pile in situ by introducing a settable material into the bore, wherein the module is configured to be releasably attachable to another module of the modular

10 displacement bore tool-head, the module comprising:

a displacement body that defines a displacement profile of the modular displacement bore tool-head, wherein the displacement body comprises at least one external protrusion, and wherein the at least one external protrusion comprises at least one helical flight

15 configured such that the defined displacement profile comprises a helical profile for creating, in use, a bore via displacement having a helical profile along the bore’s length;

means for receiving/transmitting torque from/to the another module of the modular displacement bore tool-head.

an end module of the modular displacement bore tool-head, and/or a drive coupling interconnector module of the modular displacement

25 bore tool-head.

3. The module of any previous claim, wherein the means tor receiving/transmitting torque comprises a first drive coupling configured to engage with a drive coupling of:

30 an end module of the modular displacement bore tool-head, or a drive coupling interconnector module of the modular displacement bore tool-head.

a drive coupling interconnector module of the modular displacement bore tool-head, or

5 an end module of the modular displacement bore tool-head.

5. The module of any previous claim, comprising a substantially cylindrical member having a drive coupling at each end, wherein each drive coupling is fixedly secured to the cylindrical member such that torque is able to be

10 transmitted from one drive coupling to the other via the cylindrical member itself.

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7. The module of any previous claim, wherein the module comprises an aperture therethrough for allowing the passage of a settable material therethrough.

8. The module of any previous claim, wherein the module is manufactured from iron.

9. A modular displacement bore tool-head for use in continuous helical displacement boring for creating a bore for a forming pile in situ by introducing a settable material into the bore, the modular displacement bore tool-head comprising:

30 the module of any one or more of previous claims 1 to 8;

a drive coupling interconnector module of the modular displacement bore tool-head, wherein the drive coupling interconnector module is configured to be releasably attachable to the module of any one or more of previous claims 1 to 8, the drive coupling interconnector module comprising:

a first drive coupling configured to engage with and receive torque from a drive coupling of a drive shaft; and

5 a second drive coupling configured to engage with and transmit torque to a drive coupling of the module of any one or more of previous claims 1 to 8.

10. The modular displacement bore tool-head of claim 9, wherein the 10 drive coupling interconnector module further comprises an aperture therethrough for allowing the passage of a settable material therethrough.

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11. The modular displacement bore tool-head of claim 9 or 10 further comprising:

an end module of the modular displacement bore tool-head, wherein the end module is configured to be releasably attachable to module of any one or more of previous claims 1 to 8, the end module comprising:

a first drive coupling configured to engage with and receive torque from a drive coupling of the module of any one or more of previous claims 1 to 8.

12. The modular displacement bore tool-head of claim 11, wherein the end module further comprises one or more of:

25 a substantially frustro-conical shaped member / lead taper, an auger, one or more cutting teeth, one or more cutting teeth holders, and an end cap to cover an aperture of the end module.

13. The modular displacement bore tool-head of claim 11 or 12, wherein the end module comprises an aperture therethrough for allowing the passage of a settable material therethrough.

14. The modular displacement bore tool-head of any one or more of claims 9 to 13, wherein the modular displacement bore tool-head is configured such that, in use when rotatably driven into the ground, the

5 modular displacement bore tool-head laterally displaces the ground to form a bore.

15. An apparatus for forming a pile comprising one or more of: the module of previous claims 1 to 8,and

10 the modular displacement bore tool-head of claims 9-14;