GB2605804A

GB2605804A - A system and method for slip forming/jump forming of a concrete structure

Info

Publication number: GB2605804A
Application number: GB2105262.6A
Authority: GB
Inventors: Paul O'flynn Donal; Smith David
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-04-13
Filing date: 2021-04-13
Publication date: 2022-10-19
Also published as: WO2022218812A1; GB202105262D0

Abstract

A system 10 for slip forming or jump forming of a concrete structure comprising a plurality of yokes 11 and a concrete receiving form 12 attachable to said yokes and configured to accept and shape concrete. Jacks 13 are provided for effecting vertical movement of said yokes . The system comprises an arrangement 24 for deployment of reinforcement elements (Figure 4) which is configured to deploy reinforcement elements 14 in an automated manner. The system may include a beam extending between a pair of adjacent yokes, for supporting the reinforcement deployment elements. The reinforcement deployment may include a robotic arm for applying ties to reinforcement elements or spacer elements. The system may include a means for supplying concrete. There may also be a control arrangement comprising a processor to drive and synchronise the components. Also claimed is a method of slip forming/jump forming.

Description

A SYSTEM AND METHOD FOR SLIP FORMING/JUMP FORMING OF A CONCRETE

STRUCTURE

Field of the Invention

This invention relates to a system and method for slip forming/jump forming of a concrete structure, and in particular to a system and method for slip forming/jump forming of a concrete structure in a substantially automated manner.

Background of the invention

Slip forming and jump forming are well known processes in civil engineering. Typically, these processes involve pouring concrete into a concrete receiving form to create a concrete layer. Reinforcement in the form of horizontal, cross-sectional, and vertical re-bar elements and horizontal and vertical tendon ducts may be deployed within the form prior to pouring to reinforce the structure and allow for subsequent post tensioning. The reinforcement elements may also be tied at horizontal-vertical interfaces, and spacers may also be deployed. Concrete is then poured. Once a poured layer is partially set, the form, which is attached to yokes at each longitudinal end, is raised vertically and positioned to repeat the process and form a further layer on top of the already at least partially set layer. Jacks are provided and are operable to raise the yokes and attached form. This layering process is repeated until sufficient layers have been formed to reach a desired height for the structure. Whilst the process is useful, in particular in the formation of towers, silos, caissons and the like, the deployment of reinforcement, tendon ducts, tying of the same, and application of spacers can be extremely labour intensive. Moreover, as the form must generally be moved on a strict fimescale dictated by the setting of the concrete, it can sometimes lead to difficulties in completing all of the necessary steps in time and with sufficient consistency and accuracy.

It is desirable to provide a slip forming/jump forming process wherein the deployment of reinforcement elements is carried out in a less labour intensive and more consistent manner.

Summary of the Invention

According to the invention there is provided a system for slip forming or jump forming of a concrete structure comprising a plurality of yokes; a concrete receiving form attachable to said yokes and configured to accept and shape concrete; a means for effecting vertical movement of said yokes; and means for deployment of reinforcement elements; wherein the at least one means for deployment of reinforcement elements is configured to deploy reinforcement elements in an automated manner.

Ideally the reinforcement elements comprise one or all of vertical reinforcement members, horizontal reinforcement members, vertical tendon ducts, horizontal tendon ducts, ties, and/or spacers.

Preferably, the reinforcement elements are deployed in the concrete receiving form prior to pouring/pumping of concrete thereinto such that when the concrete is set the reinforcement elements are embedded in the set concrete.

Ideally, the means for deployment of reinforcement elements is configured to deploy reinforcement elements in an automated manner along an X, Y,Z Cartesian coordinate system wherein the X axis extends laterally across the concrete receiving form, the Y axis extends longitudinally along the concrete receiving form, and the Z axis extends vertically.

Preferably, the reinforcement elements comprise one or all of vertical reinforcement members along the Z axis plane, horizontal reinforcement members along the Y axis plane, cross-sectional or laterally extending reinforcement members along the X axis plane, vertical tendon ducts, horizontal tendon ducts, ties, and/or spacers.

Preferably, the vertical and horizontal reinforcement members and/or the cross-sectional or laterally extending reinforcement members are steel re-bar members, basalt rebar members or glass fibre reinforced rebar members.

Advantageously, the manual and time consuming task of deploying reinforcement members such as re-bar and associated ties, and other reinforcement elements such as tendon ducts and spacers is automated reducing time to prepare each layer of the slip or jump form for concrete pour.

Preferably, the system comprises at least one beam which extends between each pair of adjacent 25 yokes of the plurality of yokes, the at least one beam being configured to support and/or guide the means for deployment of reinforcement elements.

Ideally, the system comprises a plurality of beams extending between each pair of adjacent yokes of the plurality of yokes, the beams being configured to support and/or guide the means for deployment 30 of reinforcement elements Ideally, the system comprises three beams extending between each pair of adjacent yokes of the plurality of yokes the beams being configured to support and/or guide the means for deployment of reinforcement elements.

Preferably, one of the three beams is a central beam which extends centrally between two adjacent yokes at their respective upper ends Ideally, the three beams further comprise and inner and outer beams that extend between said 40 adjacent yokes either side of the central beam and at a lower location on the respective yokes.

Preferably, the system comprises an inner working deck locatable on an inner side of the yokes.

Ideally, the system comprises an outer working deck locatable on an outer side of said yokes.

Preferably, the working decks are movable vertically with said yokes.

Ideally, when referring to inner and outer, inner is in relation to the interior of the structure which is to be formed using the slip forming or jump forming system and outer is in relation to the exterior of said structure.

Preferably, the means for deployment of reinforcement elements comprises means for deploying the generally horizontal reinforcement members and means for deploying the generally vertical reinforcement members.

Ideally, the inner beam comprises an inner beam guide rail extending generally longitudinally therea long.

Alternatively, the inner beam may comprise an inner beam guide rail formed integrally therewith or may act itself as an inner beam guide rail.

Preferably, the inner beam guide rail is in operable engagement with an inner carriage configured to travel along said inner beam guide rail.

Ideally, said inner carriage comprising an inner deployment arm.

Ideally, the inner deployment arm is configured to be rotatable such that the inner deployment arm or any reinforcement members that may project from its upper end may pass beneath the yokes.

Preferably, the inner deployment arm comprises a first portion mountable to the inner carriage and a 30 downwardly depending portion attachable to the first portion which, at a default position, depends generally vertically downwardly from the first portion.

Preferably, a rotatable joint is provided between the first and downwardly depending portions of the inner deployment arm.

Ideally, the rotatable joint is configured to permit rotation of the generally downwardly depending portion from its default generally vertically depending position wherein it is perpendicular to the inner beam to positions wherein it is generally 90 degrees to either side such that it is generally parallel to the inner beam, this being the maximum rotation possible but rotational positions between the default position and maximum rotation of 90 degrees may be adopted.

Preferably, the inner deployment arm is an inner L-shaped cantilever deployment arm.

Ideally, the system comprises a drive means for driving movement of the inner carriage bidirectionally along the inner guide rail.

Preferably, the drive means is a motor operably coupled to drive movement of the inner carriage bidirectionally along the inner guide rail.

Preferably, the inner carriage further comprises a vertical reinforcement member dispensing/storage 10 element.

Ideally, the inner deployment arm further comprises a vertical reinforcement member grip element configured to grip a vertically extending reinforcement member and draw said reinforcement member generally vertically downwards from the vertical reinforcement member dispensing/storage element.

Preferably, the grip element comprises a robotic clamp configured to grip and release the reinforcement as required during the deployment process.

Preferably, the inner carriage further comprises a vertical reinforcement cutting device configured to 20 cut said vertical reinforcement such that a length of vertical reinforcement may be deployed in the concrete receiving form.

Ideally, the cutting device is an electric saw such as a circular saw or chop saw.

Alternatively, the vertical reinforcement member dispensing/storage element comprises a container for housing a plurality of pre-cut sections of vertical reinforcement members.

Ideally, the vertical reinforcement member dispensing/storage element comprises a release mechanism configured to release individual pre-cut sections of vertical reinforcement members from 30 the container.

Advantageously, pre-cut sections of vertical reinforcement members may be deployed in the concrete receiving form.

Preferably, the inner deployment arm further comprises a horizontal reinforcement deployment element.

Ideally, the horizontal reinforcement deployment element comprises at least one horizontal reinforcement grip element configured to grip horizontal reinforcement and draw said horizontal 40 reinforcement from a horizontal reinforcement dispensing/storage element.

Preferably, the horizontal reinforcement dispensing/storage element is locatable on an adjacent working deck and most preferably locatable on the inner working deck.

Ideally, the inner deployment arm comprises a horizontal reinforcement cutting device configured to 5 cut said horizontal reinforcement such that a length of horizontal reinforcement may be deployed in the concrete receiving form.

Alternatively, the inner deployment arm further comprises a horizontal reinforcement deployment element comprising a container for housing a plurality of pre-cut sections of horizontal reinforcement 10 members.

Preferably, the horizontal reinforcement deployment element comprises a release mechanism configured to release individual pre-cut sections of horizontal reinforcement members from said container.

Ideally, the horizontal reinforcement members can be cut to a specific length as required.

Advantageously, pre-cut sections of horizontal reinforcement members may be deployed in the concrete receiving form.

Ideally, the outer beam comprises an outer beam guide rail extending generally longitudinally therealong.

Alternatively, the outer beam may comprise an outer beam guide rail formed integrally therewith or 25 may act itself as an outer beam guide rail.

The outer beam guide rail is in operable engagement with an outer carriage configured to travel along said outer beam guide rail.

Preferably, the outer carriage comprises an outer deployment arm.

Ideally, the outer deployment arm is configured to be rotatable such that the outer deployment arm or any reinforcement members that may project from its upper end may pass beneath the yokes.

Preferably, the outer deployment arm comprises a first portion mountable to the outer carriage and a downwardly depending portion attachable to the first portion which, at a default position, depends generally vertically downwardly from the first portion.

Preferably, a rotatable joint is provided between the first and downwardly depending portions of the 40 outer deployment arm.

Ideally, the rotatable joint is configured to permit rotation of the generally downwardly depending portion from its default generally vertically depending position wherein it is perpendicular to the outer beam to positions wherein it is generally 90 degrees to either side such that it is generally parallel to the outer beam, this being the maximum rotation possible but rotational positions between the default position and maximum rotation of 90 degrees may be adopted.

Preferably, the outer deployment arm is an outer L-shaped cantilever deployment arm.

Ideally, the system comprises a drive means for driving movement of the outer carriage bi10 directionally along the outer guide rail.

Preferably, the drive means is a motor operably coupled to drive movement of the outer carriage bidirectionally along the outer guide rail.

Ideally, the outer carriage further comprises a vertical reinforcement member dispensing/storage element.

Preferably the outer deployment arm further comprises a vertical reinforcement member grip element configured to grip a vertically extending reinforcement member and draw said reinforcement member 20 generally vertically downwards from the vertical reinforcement member dispensing/storage element.

Ideally, the outer carriage further comprising a vertical reinforcement cutting device configured to cut said vertical reinforcement such that a length of vertical reinforcement may be deployed in the concrete receiving form.

Ideally, the vertical reinforcement member dispensing/storage element comprises a release mechanism configured to release individual pre-cut sections of vertical reinforcement members from said container.

Ideally, the outer deployment arm further comprises a horizontal reinforcement deployment element.

Preferably, the horizontal reinforcement deployment element comprises at least one horizontal reinforcement grip element configured to grip horizontal reinforcement and draw said horizontal 40 reinforcement from a horizontal reinforcement dispensing/storage element.

Preferably, the horizontal reinforcement dispensing/storage element is locatable on an adjacent working deck and most preferably locatable on the outer working deck.

Ideally, the outer deployment arm comprises horizontal reinforcement cutting device configured to 5 cut said horizontal reinforcement such that a length of horizontal reinforcement may be deployed in the concrete receiving form.

Alternatively, the outer deployment arm further comprises a horizontal reinforcement deployment element comprising a container for housing a plurality of pre-cut sections of horizontal reinforcement 10 members.

Ideally, the horizontal reinforcement deployment element comprises a release mechanism configured to release individual pre-cut sections of horizontal reinforcement members from said container.

Advantageously, said pre-cut sections of horizontal reinforcement members may be deployed in the concrete receiving form.

Ideally, the means for deployment of reinforcement elements further comprises means for deploying 20 tendon duct members.

Preferably, the central beam comprises a central beam guide rail extending generally longitudinally therealong.

Alternatively, the central beam may comprise a central beam guide rail formed integrally therewith or may act itself as a central beam guide rail.

Ideally, the central beam guide rail is in operable engagement with a central carriage configured to travel along said central beam guide rail.

Preferably said central carriage comprises a central deployment arm.

Ideally, the central deployment arm is configured to be rotatable such that the central deployment arm or any reinforcement members that may project from its upper end may pass beneath the yokes.

Preferably, the central deployment arm comprises a first portion mountable to the central carriage and a downwardly depending portion attachable to the first portion which, at a default position, depends generally vertically downwardly from the first portion.

Preferably, a rotatable joint is provided between the first and downwardly depending portions of the central deployment arm.

Ideally, the rotatable joint is configured to permit rotation of the generally downwardly depending portion from its default generally vertically depending position wherein it is perpendicular to the central beam to positions wherein it is generally 90 degrees to either side such that it is generally parallel to the central beam, this being the maximum rotation possible but rotational positions between the default position and maximum rotation of 90 degrees may be adopted.

Preferably, the central deployment arm is a central L-shaped cantilever deployment arm.

Ideally, the system comprising a drive means for driving movement of the central carriage bidirectionally along the central guide rail.

Preferably, the drive means is a motor operably coupled to drive movement of the central carriage bidirectionally along the central guide rail.

Ideally, the central carriage further comprises a vertical tendon duct dispensing/storage element.

Preferably, the central deployment arm further comprises a vertical tendon duct grip element configured to grip a vertically extending tendon duct and draw said tendon duct generally vertically 20 downwards from the vertical tendon duct dispensing/storage element.

Ideally, the central carriage further comprises a vertical tendon duct cutting device configured to cut said vertical tendon duct such that a length of vertical tendon duct may be deployed in the concrete receiving form.

Alternatively, the vertical tendon duct dispensing/storage element comprises a container for housing a plurality of pre-cut sections of vertical tendon ducts.

Ideally, the vertical tendon duct dispensing/storage element comprising a release mechanism 30 configured to release individual pre-cut sections of vertical tendon ducts from said container..

Advantageously, pre-cut sections of vertical tendon ducts may be deployed in the concrete receiving form.

Preferably, the central deployment arm further comprises a horizontal tendon duct deployment element.

Ideally, the horizontal tendon duct deployment element comprises at least one horizontal tendon duct grip element configured to grip horizontal tendon duct and draw said horizontal tendon duct from a 40 horizontal tendon duct dispensing/storage element.

Preferably, the horizontal tendon duct dispensing/storage element is locatable on an adjacent working deck and most preferably locatable on the inner working deck.

Ideally, the central deployment arm comprises a horizontal tendon duct cutting device configured to 5 cut said horizontal tendon duct such that a length of horizontal reinforcement may be deployed in the concrete receiving form.

Alternatively, the horizontal tendon duct deployment element comprises a container for housing a plurality of pre-cut sections of horizontal tendon ducts.

Preferably, the horizontal tendon duct deployment element comprises a release mechanism configured to release individual pre-cut sections of horizontal tendon duct from said container.

Advantageously, pre-cut sections of horizontal tendon duct may be deployed in the concrete 15 receiving form.

Ideally, the means for deployment of reinforcement elements further comprises at least one robotic arm configured for applying ties to reinforcement elements.

Preferably, the at least one robotic arm comprises a tying mechanism similar to that found on a traditional tying tool currently used for applying ties in the field of slip forming/jump forming.

Preferably, the at least one robotic arm may also place spacer elements.

Ideally, the at least one robotic arm may also cut reinforcement elements where required.

Preferably, the at least one robotic arm is locatable on the central beam.

Ideally, a plurality of robotic arms are dispersed along the central beam longitudinally.

Advantageously, said plurality of robotic arms may access the entirety of the concrete receiving form between adjacent yokes.

Preferably, the at least one robotic arm is movably mountable to the central beam via a robotic arm 35 carriage.

Ideally, the system further comprises means for supplying concrete to the concrete receiving form.

Preferably, the means for supplying concrete comprises a hose connected to a source of concrete at 40 a first end, said source of concrete being pumped along said hose to an outlet at the second end thereof.

Preferably, the hose is retained proximal its outlet by a hose carriage such that the outlet of the hose is directed towards the concrete receiving form.

Ideally, the system is configured to vibrate the concrete to ensure air voids are removed therefrom.

Preferably, the system comprises a vibrating formwork or a vibrating rod that would be placed into the concrete.

Ideally, the hose carriage is operably attachable to one of the beams via a hose guide rail such that the hose may be moved along the guiderail to direct concrete into the concrete receiving form along its longitudinal length.

Preferably, the hose carriage is operably attachable to the inner beam via the hose guide rail.

Ideally, the system comprises a control arrangement, the control arrangement comprising a processor in operable communication with a computer readable memory means, the computer readable memory means comprising software stored thereon that when executed by the processor controls and/or synchronises movement of one or all of the various components of the means for deployment of reinforcement elements, the movement and supply of concrete from the means from supplying concrete, and the at least one robotic arm.

Preferably, the control arrangement is configured to read design drawings from a design software package and the software of the control arrangement is configured to control and/or synchronise movement of one or all of the various components of the means for deployment of reinforcement elements, the movement and supply of concrete from the means from supplying concrete, and the at least one robotic arm based upon the design drawings.

Advantageously, synchronised deployment of reinforcement members, tendon ducts, ties and or 30 spacers may be accomplished prior to supplying concrete to the concrete receiving form, all with minimal operator intervention.

Optionally, the control arrangement comprises one or more sensors configured to determine the location/positioning of the reinforcement elements and/or one or more of the various components of the means for deployment of reinforcement elements, the movement and supply of concrete from the means from supplying concrete, and the at least one robotic arm, said one or more sensors being in operable engagement with the processor and/or the computer readable memory means such that readings from said one or more sensors may aid in the control of the various components of the means for deployment of reinforcement elements.

Ideally, the one or more sensors are configured to determine the position of the reinforcement elements in order to apply ties thereto and identify where overlaps in reinforcement elements should Occur.

Ideally, the control arrangement comprises means for receiving drawings, the software being configured to define the size, length position, spacing etc for the reinforcement elements and using these parameters to control and/or synchronise movement of one or all of the various components of the means for deployment of reinforcement elements, the movement and supply of concrete from the means from supplying concrete, and the at least one robotic arm.

According to a second aspect of the invention there is provided a method of slip forming/jump forming a concrete structure comprising the steps of: automatically deploying vertical reinforcement members from a means for automatic deployment of reinforcement elements into a concrete receiving form configured to receive and shape concrete, the vertical reinforcement elements being secured to vertical reinforcement members of an already complete slip formed layer immediately below or secured at ground level where the layer being currently formed is a first layer, the concrete receiving form being attachable between two adjacent yokes and movable vertically with said yokes under the influence of a means for effecting vertical movement of said yokes; automatically deploying horizontal reinforcement members into the concrete receiving form from the means for 20 automatic deployment of reinforcement elements; tying the horizontal and vertical reinforcement elements at intersections thereof using a robotic arm mountable on the at least one beam.

Preferably, the method comprising automatically deploying vertical tendon ducts from the means for automatic deployment of reinforcement elements.

Ideally, the method comprising automatically deploying horizontal tendon ducts from the means for automatic deployment of reinforcement elements.

Preferably, the method comprising pouring concrete into the concrete receiving form.

Ideally, once the poured concrete is at least partially set, the method comprising moving the yokes vertically upwards in one movement or at a constant gradual rate of movement and repeating the above steps to form a further layer, and repeating the formation of layers until a desired height is reached.

Brief description of the drawings

An embodiment of the invention is now described by way of example and with reference to the accompanying drawings in which: Figure 1 is a perspective view of a yoke forming part of a system for slip forming or jump forming, the yoke comprising part of an arrangement for deployment of reinforcement elements; Figure 2 is a perspective view of a portion of a system for slip forming or jump forming showing an 5 arrangement for deployment of reinforcement elements extending between two adjacent yokes; Figure 3 is a cross-sectional conceptual view of a system for slip forming or jump forming; Figure 4 is a side conceptual view of a part of a system for slip forming or jump forming showing a 10 deployment arm situated on a carriage, the deployment arm being rotatable; Figure 5 is a side conceptual view of a part of a system for slip forming or jump forming showing an arrangement for supplying concrete to a concrete receiving form; Figure 6 is a conceptual view of a robotic arm of a system for slip forming or jump forming, the robotic arm comprising a cutting device for cutting reinforcement elements; Figure 7 is a conceptual view of a robotic arm of a system for slip forming or jump forming, the robotic arm comprising a tying mechanism for applying ties to reinforcement elements; and Figure 8 is a conceptual view of a robotic arm of a system for slip forming or jump forming, the robotic arm comprising a mechanism for applying spacers to reinforcement elements.

Detailed Description of the drawings

The present teaching will now be described with reference to an exemplary system and method for slip forming or jump forming of a concrete structure. It will be understood that the exemplary system and method is provided to assist in an understanding of the present teaching and are not to be construed as limiting in any fashion. Furthermore, elements or components that are described with reference to any one Figure may be interchanged with those of other Figures or other equivalent elements without departing from the spirit of the present teaching.

Referring now to the Figures there is illustrated a system 10 for slip forming or jump forming of a concrete structure comprising a plurality of yokes 11 and a concrete receiving form 12 attachable to said yokes 11 and configured to accept and shape concrete. Jacks (not shown) are provided for effecting vertical movement of said yokes 11. The system comprises an arrangement 24 for deployment of reinforcement elements which is configured to deploy reinforcement elements 14 in an automated manner. The reinforcement elements 14 comprise one or all of vertical reinforcement members 15, horizontal reinforcement members 16, vertical tendon ducts (not shown), horizontal tendon ducts (not shown), ties 19, and/or spacers 20. The reinforcement elements 14 are deployed in the concrete receiving form 12 prior to pouring/pumping of concrete thereinto such that when the concrete is set the reinforcement elements 14 are embedded, or at least partially embedded, in the set concrete. The general apparatus required for slip forming and jump forming is well known to the skilled person and as such the details of yokes, jacking of the yokes, working decks, and concrete forms will not be described in detail herein, nor will the general process of gradually or in steps moving the form upwards to create layers of reinforced concrete as again this is well known to the skilled person. The present invention is concerned with improvement of this process by making application of reinforcement elements and associated infrastructure less time consuming and labour intensive. Advantageously, the manual time consuming task of deploying reinforcement members such as re-bar and associated ties, and other reinforcement elements such as tendon ducts and spacers is automated, reducing time to prepare each layer of the slip or jump form for concrete pour. The vertical and horizontal reinforcement members 15, 16 are typically vertical and horizontally deployed steel re-bar members 15, 16. The vertical and horizontal tendon duct members are steel tendon ducts designed to allow passage of tensioning tendons through the structure such that post tensioning may be conducted. Tendon ducts may not be required in all applications, only where post tensioning is desirable.

The system 10 comprises at least one beam 21, 22, 23 which extends between each pair of adjacent yokes 11a, llb of the plurality of yokes 11. The at least one beam 21, 22, 23 is configured to support and/or guide the arrangement 24 for deployment of reinforcement elements. In a preferred embodiment, the system comprises three beams 21, 22, 23 extending between each pair of adjacent yokes 11a, llb of the plurality of yokes. As is best illustrated in Figure 2, one of the three beams is a central beam 21 which extends generally centrally between two adjacent yokes 11a, llb at their respective upper ends. Centrally in this case is in reference to the widthwise dimension of the concrete receiving form 12 which extends between said adjacent yokes 11a, 11b. The three beams further comprise and inner and outer beams 22, 23 that extend between said adjacent yokes 112, llb on either lateral side of the central beam 22 and at a lower location on the respective yokes 11a, 11b. The beams generally extend horizontally between said adjacent yokes 11a, 11 b. It should be noted that the present invention is generally herein described in reference to two adjacent yokes 11a, 11b, however it should be understood that a slip forming/jump forming system is typically comprised of a sequence of yokes distributed to generally support forms to create the cross-sectional shape of the structure to be constructed. Thus, the description "between adjacent yokes 11a, Ii b' herein should be understood to apply to each set of adjacent yokes in such a sequence of yokes. In this manner, the beams 21, 22, 23 extend between each set of adjacent yokes such that when all beams are attached they form generally continuous beams around the entire sequence of yokes 11. Alternatively, the beams could be formed as continuous beams and attached to the entire sequence of yokes in this state. In addition, the beams may be curved beams, as is shown in Figure 2, such that they generally adhere to the curvature of the structure to be slip formed/jump formed. The curved beams 21, 22, 23 follow a curved path between adjacent yokes 11a, 11b.

The system 10 comprises an inner working deck 28 locatable on an inner side 29 of the yokes 11a, 11b and an outer working deck 30 locatable on an outer side 31 of said yokes 11a, 11b. The working decks 28, 30 are movable vertically with said yokesl 1a, 11b. When referring to inner and outer, inner is in relation to the interior of the structure which is to be formed using the slip forming or jump forming system and outer is in relation to the exterior of said structure. The arrangement 24 for deployment of reinforcement elements comprises sub-arrangements 32, 70 for deploying generally horizontal reinforcement members 16 and for deploying the generally vertical reinforcement members 15.

The inner beam 22 supports a sub-arrangement 32 for deploying generally horizontal reinforcement members 16 and for deploying the generally vertical reinforcement members 15. The inner beam comprises an inner beam guide rail 33 extending generally longitudinally therealong. The inner beam guide rail 33 is in operable engagement with an inner carriage 34 configured to travel along said inner beam guide rail 33. The carriage 34 and guide rail 33 may be of any suitable type that would be known to the skilled person for effecting longitudinal travel. The inner carriage 34 comprises an inner deployment arm 35. The inner deployment arm 35 is configured to be rotatable such that the inner deployment arm 35 or any reinforcement members 15 that may project from its upper end may pass beneath the yokes 11a, 11b, this can be seen for example in Figure 4. In this manner, the carriage may pass from an inner beam between a first set of adjacent yokes 11a, llb beneath a yoke and to an inner beam between the next set of adjacent yokes 11b, 11c. The inner deployment arm 35 comprises a first portion 36 mountable to the inner carriage 34 and a downwardly depending portion 37 attachable to the first portion 36 which, at a default position, depends generally vertically downwardly from the first portion 36. A rotatable joint 38 is provided between the first and downwardly depending portions 36, 37 of the inner deployment arm 35 which is configured to permit rotation of the generally downwardly depending portion from its default generally vertically depending position to two separate positions 90 degrees to either side such that it is generally horizontally extending, or at least between generally vertically depending and generally horizontally extending, this being the maximum rotation possible but rotational positions between the default position and maximum rotation of 90 degrees may be adopted. The rotatable joint 38 permits 180 degrees of rotation of the inner deployment arm 35 thereabouts. In preferable embodiments, the inner deployment arm 35 is an inner L-shaped cantilever deployment arm 35. The system comprises a drive (not shown) for driving movement of the inner carriage 34 bi-directionally along the inner guide rail 33. The drive may be a motor such as an electric motor, or any other such suitable drive that would be well known to the skilled person The inner carriage 34 further comprises a vertical reinforcement member dispensing/storage element 39 and a vertical reinforcement member grip element 40 configured to grip a vertically extending reinforcement member 15 and draw said reinforcement member generally vertically downwards from the vertical reinforcement member dispensing/storage element 39. In preferable embodiments, the grip element comprises a robotic clamp. The inner carriage may further comprise a vertical reinforcement cutting device 41 configured to cut said vertical reinforcement 15 such that a length of vertical reinforcement may be deployed in the concrete receiving form 12. In preferable embodiments the cutting device is an electrically powered saw such as a circular saw or chop saw, or may be an electrically powered grinder device. The cutting device 41 may also be deployed on the central 21, 23 or outer beams and is configured such that it is movable such that it has access to the entirety of the concrete receiving form 12.

In some embodiments, the vertical reinforcement member dispensing/storage element 39 comprises a container (not shown) for housing a plurality of pre-cut sections of vertical reinforcement members 15. The vertical reinforcement member dispensing/storage element 39 comprises a release mechanism (not shown) configured to release individual pre-cut sections of vertical reinforcement members from the container. Advantageously, pre-cut sections of vertical reinforcement members 15 may be deployed in the concrete receiving form 12.

The inner deployment arm 35 also preferably comprises a horizontal reinforcement deployment element 44. The horizontal reinforcement deployment element 44 comprises at least one horizontal reinforcement grip element 45 configured to grip horizontal reinforcement 16 and draw said horizontal reinforcement 16 from a horizontal reinforcement dispensing/storage element 46. The horizontal reinforcement dispensing/storage element 46 is preferably located on an adjacent working deck and most preferably located on the inner working deck 28. The inner deployment arm 35 comprises a horizontal reinforcement cutting device configured to cut said horizontal reinforcement 16 such that a length of horizontal reinforcement 15 may be deployed in the concrete receiving form 12. The cutting device may be the same cutting device 41 as referred to in relation to the cutting of vertical reinforcement deployed by the inner deployment arm 35. The inner deployment arm 35 may have a plurality of horizontal reinforcement deployment elements 44 which are identical to that as described above and may be positioned on the inner deployment arm to deploy horizontal reinforcement at various depthwise positions in the concrete receiving form 12. In some embodiments, the horizontal reinforcement deployment element 44 comprises a container for housing a plurality of pre-cut sections of horizontal reinforcement members 16. The horizontal reinforcement deployment element 44 may comprise a release mechanism configured to release individual pre-cut sections of horizontal reinforcement members 16 from said container. Advantageously, pre-cut sections of horizontal reinforcement members 16 may be deployed in the concrete receiving form 12.

The outer beam 23 supports an essentially identical sub-arrangement 32 to the inner beam 22 for deploying vertical and horizontal reinforcement members 15, 16. This permits the arrangement of the inner beam 22 to deploy vertical and horizontal reinforcement to one lateral side of the concrete receiving form 12 and the arrangement of the outer beam 23 to deploy the same to the other lateral side thereof Whilst the arrangements of the inner and outer beams 22, 23 are essentially identical the arrangement of the outer beam 23 is described below for completeness.

The outer beam 23 supports a sub-arrangement 50 for deploying generally horizontal reinforcement members 16 and for deploying the generally vertical reinforcement members 15. The outer beam comprises an outer beam guide rail 53 extending generally longitudinally therealong. The outer beam guide rail 53 is in operable engagement with an outer carriage 54 configured to travel along said outer beam guide rail 53. The carriage 54 and guide rail 53 may be of any suitable type that would be known to the skilled person for effecting longitudinal travel. The outer carriage 54 comprises an outer deployment arm 55. The outer deployment arm 55 is configured to be rotatable such that the outer deployment arm 55 or any reinforcement members 15 that may project from its upper end may pass beneath the yokes 11a, 11 b. In this manner, the carriage 54 may pass from an outer beam between a first set of adjacent yokes 11a, llb beneath a yoke and to an outer beam between the next set of adjacent yokes 11b, 11c. The outer deployment arm 55 comprises a first portion 56 mountable to the outer carriage 54 and a downwardly depending portion 57 attachable to the first portion 56 which, at a default position, depends generally vertically downwardly from the first portion 56. A rotatable joint is provided between the first and downwardly depending portions 56, 57 of the outer deployment arm 55 which is configured to permit rotation of the generally downwardly depending portion from its default generally vertically depending position to two separate positions 90 degrees to either side such that it is generally horizontally extending, or at least between generally vertically depending and generally horizontally extending, this being the maximum rotation possible but rotational positions between the default position and maximum rotation of 90 degrees may be adopted. The rotatable joint permits 180 degrees of rotation of the outer deployment arm 55 thereabouts. Whilst the rotatable connection is shown in relation to the inner deployment arm 35 in Figure 4, the same arrangement may be equally applied to the outer deployment arm 55 to facilitate the aforementioned rotation. In preferable embodiments, the outer deployment arm 55 is an outer L-shaped cantilever deployment arm 55. The system comprises a drive (not shown) for driving movement of the outer carriage 54 bi-directionally along the outer guide rail 53. The drive may be a motor such as an electric motor, or any other such suitable drive that would be well known to the skilled person.

The outer carriage 54 further comprises a vertical reinforcement member dispensing/storage element 59 and a vertical reinforcement member grip element 60 configured to grip a vertically extending reinforcement member 15 and draw said reinforcement member generally vertically downwards from the vertical reinforcement member dispensing/storage element 59. The outer carriage may further comprise a vertical reinforcement cutting device configured to cut said vertical reinforcement 15 such that a length of vertical reinforcement may be deployed in the concrete receiving form 12.

In some embodiments, the vertical reinforcement member dispensing/storage element 59 comprises a container for housing a plurality of pre-cut sections of vertical reinforcement members 15. The vertical reinforcement member dispensing/storage element 59 comprises a release mechanism 40 configured to release individual pre-cut sections of vertical reinforcement members from the container. Advantageously, pre-cut sections of vertical reinforcement members 15 may be deployed in the concrete receiving form 12.

The outer deployment arm 55 also preferably comprises a horizontal reinforcement deployment element 64. The horizontal reinforcement deployment element 64 comprises at least one horizontal reinforcement grip element 65 configured to grip horizontal reinforcement 16 and draw said horizontal reinforcement 16 from a horizontal reinforcement dispensing/storage element 66. The horizontal reinforcement dispensing/storage element 66 is preferably located on an adjacent working deck and most preferably located on the outer working deck 30. The outer deployment arm 55 comprises a horizontal reinforcement cutting device 67 configured to cut said horizontal reinforcement 16 such that a length of horizontal reinforcement 15 may be deployed in the concrete receiving form 12. In some embodiments, the horizontal reinforcement deployment element 64 comprises a container for housing a plurality of pre-cut sections of horizontal reinforcement members 16. The horizontal reinforcement deployment element 64 may comprise a release mechanism configured to release individual pre-cut sections of horizontal reinforcement members 16 from said container. Advantageously, pre-cut sections of horizontal reinforcement members 16 may be deployed in the concrete receiving form 12.

The central beam 21 supports an essentially identical sub-arrangement to the inner beam 22 and outer beam 23; however in the preferred embodiment the arrangement of the central beam 21 is for deploying vertical and horizontal tendon duct members 17, 18. Whilst the arrangements of the central beam 21 and the inner and outer beams 22, 23 are essentially identical, the arrangement of the central beam 21 is described below for completeness.

The central beam 21 supports a sub-arrangement 70 for deploying generally horizontal tendon duct members 18 and for deploying the generally vertical tendon duct members 17. The central beam 21comprises a central beam guide rail 73 extending generally longitudinally therealong. The central beam guide rail 73 is in operable engagement with a central carriage 74 configured to travel along said central beam guide rail 73. The carriage 74 and guide rail 73 may be of any suitable type that would be known to the skilled person for effecting longitudinal bi-directional travel. The central carriage 74 comprises a central deployment arm 75. The central deployment arm 75 is configured to be rotatable such that the central deployment arm 75 or any tendon duct members 17 that may project from its upper end may pass beneath the yokes 11a, 11b. In this manner, the carriage 74 may pass from a central beam between a first set of adjacent yokes 11a, 11b beneath a yoke and to a central beam between the next set of adjacent yokes 11b, 11c. The rotation is provided in a similar manner to that as shown in Figure 4 in relation to the inner deployment arm 37. Similar to the inner and outer deployment arms, the central deployment arm 75 may comprise a first portion mountable to the central carriage 74 and a downwardly depending portion 77 attachable to the first portion which, at a default position, depends generally vertically downwardly from the first portion. A rotatable joint is provided between the first and downwardly depending portions of the central deployment arm 75 which is configured to permit rotation of the generally downwardly depending portion from its default generally vertically depending position to two separate positions 90 degrees to either side such that it is generally horizontally extending, or at least between generally vertically depending and generally horizontally extending, this being the maximum rotation possible but rotational positions between the default position and maximum rotation of 90 degrees may be adopted. The rotatable joint 78 permits 180 degrees of rotation of the central deployment arm 75 thereabouts. In preferable embodiments, the central deployment arm 75 is a central L-shaped cantilever deployment arm 75. The system comprises a drive (not shown) for driving movement of the central carriage 74 bi-directionally along the central guide rail 73. The drive may be a motor such as an electric motor, or any other such suitable drive that would be well known to the skilled person.

The central carriage 74 further comprises a vertical tendon duct member dispensing/storage element 79 and a vertical tendon duct member grip element 80 configured to grip a vertically extending tendon duct member 17 and draw said tendon duct member generally vertically downwards from the vertical tendon duct member dispensing/storage element 79. The central carriage 74 may further comprise a vertical tendon duct cutting device configured to cut said vertical tendon duct 17 such that a length of vertical tendon duct may be deployed in the concrete receiving form 12. The cutting device may be the same cutting device as described in relation to cutting of reinforcement members deployed by the inner and outer deployment arms, or may be a dedicated cutting device of the same type.

In some embodiments, the vertical tendon duct member dispensing/storage element 79 comprises a container for housing a plurality of pre-cut sections of vertical tendon duct members 17. The vertical tendon duct member dispensing/storage element 79 comprises a release mechanism configured to release individual pre-cut sections of vertical tendon duct members from the container.

Advantageously, pre-cut sections of vertical tendon duct members 17 may be deployed in the concrete receiving form 12.

The central deployment arm 75 also preferably comprises a horizontal tendon duct deployment element 84. The horizontal tendon duct deployment element 84 comprises at least one horizontal tendon duct grip element 85 configured to grip horizontal tendon duct 18 and draw said horizontal tendon duct 18 from a horizontal tendon duct dispensing/storage element 86. The horizontal tendon duct dispensing/storage element 86 is preferably located on an adjacent working deck and most preferably located on the inner working deck 28. The central deployment arm 75 comprises a horizontal tendon duct cutting device configured to cut said horizontal tendon duct such that a length of horizontal tendon duct 17 may be deployed in the concrete receiving form 12. As detailed, one cutting device such as that shown in Figure 6 may be utilised to cut all reinforcement members and tendon ducts, or a plurality of such cutting devices may be provided such that each cutting activity may be provided with a dedicated cutting device. In some embodiments, the horizontal tendon duct deployment element 74 comprises a container for housing a plurality of pre-cut sections of horizontal tendon duct members 18. The horizontal tendon duct deployment element 74 may comprise a release mechanism configured to release individual pre-cut sections of horizontal tendon duct members 18 from said container. Advantageously, pre-cut sections of horizontal tendon duct members 18 may be deployed in the concrete receiving form 12.

The arrangement 24 for deployment of reinforcement elements further comprises at least one robotic arm 90, 91, 92 configured for applying ties 19 to the horizontal and vertical reinforcement members 15, 16, and to the horizontal and vertical tendon ducts 17, 18. The robotic arms 90, 91, 92 can be battery powered or powered by electrical supply cables. The ties 19 are applied at intersections of horizontal and vertical members to increase the rigidity of the structure and retain shape for concrete pouring. One robotic arm comprises a tying mechanism 93 similar to that found on a traditional tying tool currently used for applying ties in the field of slip forming/jump forming. In the preferred embodiment the system comprises three robotic arms 90, 91, 92, however it should be noted that any reasonable number of robotic arms may be deployed. One of the robotic arms 91 may also place spacer elements 20 and thus may comprise a grab mechanism 94 for lifting, manipulating, and placing spacers. Such mechanisms would be well known to the skilled person and a simple matter of choice and as such will not be described in detail herein for brevity. The spacers are placed on the outside of the reinforcement members between the reinforcement members and the concrete receiving form. The purpose of the spacers is to ensure the reinforcement members are not too close to the concrete receiving form resulting in exposure of the reinforcement members through the surface of the formed wall. One of the robotic arms 92 may also cut the horizontal and vertical reinforcement members 15, 16, and the horizontal and vertical tendon ducts 17, 18 where required and thus may comprise the aforementioned cutting device 41 thereon. Such cutting mechanisms would be well known to the skilled person and a simple matter of choice and as such will not be described in detail herein for brevity. The robotic arms are preferably located on the central beam 21 and are dispersed along the central beam 21 longitudinally in a spaced apart arrangement between the two adjacent yokes 11a, 11b. Advantageously, the robotic arms 90, 91, 92 may access the entirety of the concrete receiving form 12 between adjacent yokes 11a, 11b to carry out the aforementioned tasks of applying ties 19, cutting reinforcement elements, or placing spacers 20. The robotic arms 90, 91, 92 are movably mountable to the central beam 21 via a robotic arm carriage 96 via an arm guide rail 97.

The system further comprises an arrangement 98 for supplying concrete to the concrete receiving form 12 having a hose 99 connected to a source of concrete (not shown) at a first end, said source of concrete being pumped along said hose 99 by a pump (not shown) to an outlet 101 at the second end 102 of the hose 99. The hose 99 is retained proximal its outlet 102 by a hose carriage 103 such that the outlet 102 of the hose 99 is directed towards the concrete receiving form 12. The hose 99 may, in some embodiments, be connected to the hose carriage 103 via a hose arm 106. The hose arm 106 has a joint providing four degrees of freedom, allowing the hose 99 to be turned away from the concrete receiving form 12 such that the hose 99 may pass a yoke if needed and continue to the space between another set of adjacent yokes. Preferably, the joint of the hose arm allows the hose 99 to be turned approximately 90 degrees. The hose carriage 103 is operably attachable to one of the beams 21, 22, 23 via a hose guide rail 104 such that the hose 99 may be moved along the guiderail 104 to direct concrete into the concrete receiving 12 form along its longitudinal length. In a preferable embodiment, the hose carriage 103 is operably attachable to the inner beam 22. Once the reinforcement elements have been suitably deployed on the concrete receiving form, the concrete may then be poured automatically, reducing the need for multiple operatives and improving the uniformity and/or speed of the concrete pour. The system, in some embodiments, may comprise a plurality of arrangements 98 for supplying concrete attachable and movable as described above, such that concrete may be simultaneously poured at various locations, improving the consistency of pour and in turn improving the uniformity with which the concrete layer dries.

In addition to vertical reinforcement member deployment generally along a Z axis and horizontal reinforcement member deployment generally along a Y axis the arrangement 24 for deployment of reinforcement elements may deploy cross sectional reinforcement member generally along an X axis, wherein the X axis extends laterally across the concrete receiving form, the Y axis extends longitudinally along the concrete receiving form, and the Z axis extends vertically. Cross sectional reinforcement member deployment is similar to the horizontal and vertical deployments and can be deployed using the hose guide rail 104 utilised to supply concrete as discussed above. The cross sectional reinforcement member can be pre-cut into reinforcement member strands and contained in a moveable container on the carriage 104 which is convenient as the cross sectional reinforcement member length is similar to cross sectional or lateral dimension of the concrete receiving form 12.

The horizontal and vertical reinforcement member has to be deployed first. The cross sectional reinforcement member is deployed and the robotic arm 93, which travels in front of the cross sectional deployed reinforcement member, ties the cross sectional reinforcement member to the horizontal and vertical reinforcement member at their intersections.

It should be understood that references to the reinforcement members as rebar herein should not be construed as limiting. Any suitable form of rebar as would be well known to the skilled person may be utilised. For example, vertical rebar having a U-shaped end may be utilised and/or rebar having an I or L shape may be utilised.

The system 10 comprises a control arrangement 105, the control arrangement comprising a processor in operable communication with a computer readable memory component, the computer readable memory component comprising software stored thereon that when executed by the processor controls and/or synchronises movement of one or all of the various components of the arrangement 24 for deployment of reinforcement elements, the movement and supply of concrete from the hose 99, and the robotic arms 90, 91, 92. The control arrangement 105 may be a computer, PLC device, or any other such suitable control arrangement 105. The skilled person in the design of automated systems would be well aware of control systems for control of automatic movement and/or activation of components of a system and as such the control system will not be further described herein for brevity. Advantageously, synchronised deployment of reinforcement members 15,6, tendon ducts 17,18, ties 19 and or spacers 20 may be accomplished prior to supplying concrete to the concrete receiving form 12, all with minimal operator intervention. Optionally, the control arrangement may comprise one or more sensors (not shown) configured to determine the location/positioning of the reinforcement elements 15, 16, 17, 18, 19,20 and/or one or more of the various components of the arrangement 24 for deployment of reinforcement elements. The sensors may also determine the movement and supply of concrete and monitor the amount of concrete poured. Sensors may also be deployed to monitor movement and positioning of the robotic arms 90, 91, 92. The sensors may be any suitable sensors, again many of which would be well known to the skilled person. The sensors may also include visual recognition systems. The sensors are in operable communication, in a wired or wireless manner, with the processor and/or the computer readable memory component such that readings from said one or more sensors may aid in the control of the system 10. In preferable embodiments, the sensors are configured to determine the position of the reinforcement elements in order to apply ties thereto and identify where overlaps in reinforcement elements should occur. The control arrangement 105 has an interface which permits uploading of drawings thereto. These drawings may be generated in AutoCAD or any other such suitable drawing software. The software is configured to define the size, length position, spacing etc for the reinforcement elements and using these parameters to control and/or synchronise movement of one or all of the various components of the means for deployment of reinforcement elements, the movement and supply of concrete from the means from supplying concrete, and the at least one robotic arm. In this manner drawings may be uploaded and the software may plan and execute deployment of reinforcement elements based thereon with minimal input from an operative.

The above system may be used to carry out a method of slip forming/jump forming of a concrete structure. Beams 21, 22, 23 are attached such that they extend between adjacent yokes 11a, 11 b in a slip form/jump form system and the arrangement 24 for automatic deployment of reinforcement elements is movably attached to said beams 21, 22, 23. The method comprises automatically deploying, from the arrangement 24 for automatic deployment of reinforcement elements, vertical reinforcement members 15 into a concrete receiving form 12 configured to receive and shape concrete. The vertical reinforcement members 15 are secured to vertical reinforcement members 15 of an already formed layer immediately below or secured at ground level where the layer being currently formed is a first layer. The concrete receiving form is attachable between two adjacent yokes I la, 11 b, and movable vertically with said yokes under the influence of jacks 13 for effecting vertical movement of said yokes 11a, 11b. Horizontal reinforcement members 16 are deployed into the concrete receiving form 12 from the arrangement 24 for automatic deployment of reinforcement elements and the horizontal and vertical reinforcement members 15, 16 are tied at all or some intersections thereof using robotic arms 90, 91, 92 mountable on the central beam 21 by applying ties deployed by the robotic arms 90, 91, 92. Where required, the method comprises automated deployment of vertical tendon ducts 17 and horizontal tendon ducts 18 from the arrangement 24 for automatic deployment of reinforcement elements. The method may also comprise tying the vertical tendon ducts 17 and horizontal tendon ducts 18 at intersections thereof or at least some intersections thereof by applying ties deployed by the robotic arms 90, 91, 92. The method may also 40 comprise placement of spacers 20 by the robotic arms 90, 91, 92. Once any required reinforcement elements 14, 15, 16, 17 are suitably deployed in the concrete receiving form 12 and any required ties 19 and spacers 20 are applied, method comprises pumping concrete from the hose 99 and into the concrete receiving form 12. Once the poured concrete is at least partially set, the method comprises moving the yokes 113, 11b vertically upwards in one movement or at a constant gradual rate of movement and repeating the above steps to form a further layer, and repeating the formation of layers until a desired height is reached. The vertical height at which a new layer is formed is generally referred to as the origin of said new layer. It should be understood that the invention is not limited to the formation of structures of uniform cross-section. The concrete receiving form may be adapted or replaced at particular layers to create a tapered structure, or any other required shape. Such adaptations to the invention would be understood by the skilled person.

The invention is not limited to the embodiment(s) described herein but can be amended or modified without departing from the scope of the present invention.

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Claims

CLAIMS1. A system for slip forming or jump forming of a concrete structure comprising: a plurality of yokes; a concrete receiving form attachable to said yokes and configured to accept and shape concrete; a means for effecting vertical movement of said yokes; and means for deployment of reinforcement elements; wherein the means for deployment of reinforcement elements is configured to deploy reinforcement elements in an automated manner.
2 The system of claim 1 further comprising at least one beam which extends between each pair of adjacent yokes of the plurality of yokes, the at least one beam being configured to support and/or guide the means for deployment of reinforcement elements, preferably, the system comprising a plurality of beams and most preferably three beams comprising a central beam which extends centrally between two adjacent yokes at their respective upper ends, and inner and outer beams that extend between said adjacent yokes either side of the central beam and at a lower location on the respective yokes, preferably the system comprising an inner working deck locatable on an inner side of the yokes and/or an outer working deck locatable on an outer side of said yokes, the working decks being movable with said yokes.
3. The system of claim 2, wherein the means for deployment of reinforcement elements comprises means for deploying generally horizontal reinforcement members and means for deploying generally vertical reinforcement members, and optionally means for deploying generally cross-sectional reinforcement members.
4. The system of claim 2 or claim 3, wherein the inner beam comprises an inner beam guide rail extending generally longitudinally therealong, the inner beam guide rail is in operable engagement with an inner carriage configured to travel along said inner beam guide rail, preferably said inner carriage comprising an inner deployment arm, the system comprising a drive means for driving movement of the inner carriage bi-directionally along the inner guide rail.
5 The system of claim 4, wherein the inner carriage further comprises a vertical reinforcement member dispensing/storage element, preferably the inner deployment arm further comprising a vertical reinforcement member grip element configured to grip a vertically extending reinforcement member and draw said reinforcement member generally vertically downwards from the vertical reinforcement member dispensing/storage element, optionally, the inner carriage further comprising a vertical reinforcement cutting device configured to cut said vertical reinforcement such that a length of vertical reinforcement may be deployed in the concrete receiving form.
6. The system of claim 4, wherein the inner carriage further comprises a vertical reinforcement member dispensing/storage element, preferably the vertical reinforcement member dispensing/storage element comprising a container for housing a plurality of pre-cut sections of vertical reinforcement members, the vertical reinforcement member dispensing/storage element comprising a release mechanism configured to release individual pre-cut sections of vertical reinforcement members from said container such that said pre-cut sections of vertical reinforcement members may be deployed in the concrete receiving form.
7 The system of any of claims 4 to 6, wherein the inner deployment arm further comprises a horizontal reinforcement deployment element comprising at least one horizontal reinforcement grip element configured to grip horizontal reinforcement and draw said horizontal reinforcement from a horizontal reinforcement dispensing/storage element, preferably the horizontal reinforcement dispensing/storage element being locatable on an adjacent working deck and most preferably locatable on the inner working deck, optionally, the inner deployment arm comprising a horizontal reinforcement cutting device configured to cut said horizontal reinforcement such that a length of horizontal reinforcement may be deployed in the concrete receiving form.
8. The system of any of claims 4 to 6, wherein the inner deployment arm further comprises a horizontal reinforcement deployment element comprising a container for housing a plurality of pre-cut sections of horizontal reinforcement members, the horizontal reinforcement deployment element comprising a release mechanism configured to release individual pre-cut sections of horizontal reinforcement members from said container such that said pre-cut sections of horizontal reinforcement members may be deployed in the concrete receiving form.
9 The system of any of claims 2 to 8, wherein the outer beam comprises an outer beam guide rail extending generally longitudinally therealong, the outer beam guide rail is in operable engagement with an outer carriage configured to travel along said outer beam guide rail, preferably said outer carriage comprising an outer deployment arm, the system comprising a drive means for driving movement of the outer carriage bi-directionally along the outerguide rail.
10. The system of claim 9, wherein the outer carriage further comprises a vertical reinforcement member dispensing/storage element, preferably the outer deployment arm further comprising a vertical reinforcement member grip element configured to grip a vertically extending reinforcement member and draw said reinforcement member generally vertically downwards from the vertical reinforcement member dispensing/storage element, optionally, the outer carriage further comprising a vertical reinforcement cutting device configured to cut said vertical reinforcement such that a length of vertical reinforcement may be deployed in the concrete receiving form.
11. The system of claim 10, wherein the outer carriage further comprises a vertical reinforcement member dispensing/storage element, preferably the vertical reinforcement member dispensing/storage element comprising a container for housing a plurality of pre-cut sections of vertical reinforcement members, the vertical reinforcement member dispensing/storage element comprising a release mechanism configured to release individual pre-cut sections of vertical reinforcement members from said container such that said pre-cut sections of vertical reinforcement members may be deployed in the concrete receiving form.
12. The system of any of claims 9 to 11, wherein the outer deployment arm further comprises a horizontal reinforcement deployment element comprising at least one horizontal reinforcement grip element configured to grip horizontal reinforcement and draw said horizontal reinforcement from a horizontal reinforcement dispensing/storage element, preferably the horizontal reinforcement dispensing/storage element being locatable on an adjacent working deck and most preferably locatable on the outer working deck, optionally, the outer deployment arm comprising a horizontal reinforcement cutting device configured to cut said horizontal reinforcement such that a length of horizontal reinforcement may be deployed in the concrete receiving form.
13. The system of any of claims 9 to 11, wherein the outer deployment arm further comprises a horizontal reinforcement deployment element comprising a container for housing a plurality of pre-cut sections of horizontal reinforcement members, the horizontal reinforcement deployment element comprising a release mechanism configured to release individual precut sections of horizontal reinforcement members from said container such that said pre-cut sections of horizontal reinforcement members may be deployed in the concrete receiving form.
14. The system of any preceding claim, wherein the means for deployment of reinforcement elements further comprises means for deploying tendon duct members.
15. The system of claim 14, wherein the central beam comprises a central beam guide rail extending generally longitudinally therealong, the central beam guide rail is in operable engagement with a central carriage configured to travel along said central beam guide rail, preferably said central carriage comprising a central deployment arm, the system comprising a drive means for driving movement of the central carriage bi-directionally along the central guide rail.
16. The system of claim 15, wherein the central carriage further comprises a vertical tendon duct dispensing/storage element, preferably the central deployment arm further comprising a vertical tendon duct grip element configured to grip a vertically extending tendon duct and draw said tendon duct generally vertically downwards from the vertical tendon duct dispensing/storage element, optionally, the central carriage further comprising a vertical tendon duct cutting device configured to cut said vertical tendon duct such that a length of vertical tendon duct may be deployed in the concrete receiving form.
17. The system of claim 15, wherein the central carriage further comprises a vertical tendon duct dispensing/storage element, preferably the vertical tendon duct dispensing/storage element comprising a container for housing a plurality of pre-cut sections of vertical tendon ducts, the vertical tendon duct dispensing/storage element comprising a release mechanism configured to release individual pre-cut sections of vertical tendon ducts from said container such that said pre-cut sections of vertical tendon ducts may be deployed in the concrete receiving form.
18 The system of any of claims 15 to 17, wherein the central deployment arm further comprises a horizontal tendon duct deployment element comprising at least one horizontal tendon duct grip element configured to grip horizontal tendon duct and draw said horizontal tendon duct from a horizontal tendon duct dispensing/storage element, preferably the horizontal tendon duct dispensing/storage element being locatable on an adjacent working deck and most preferably locatable on the inner working deck, optionally, the central deployment arm comprising a horizontal tendon duct cutting device configured to cut said horizontal tendon duct such that a length of horizontal reinforcement may be deployed in the concrete receiving form.
19 The system of any of claims 15 to 17, wherein the central deployment arm further comprises a horizontal tendon duct deployment element comprising a container for housing a plurality of pre-cut sections of horizontal tendon ducts, the horizontal tendon duct deployment element comprising a release mechanism configured to release individual pre-cut sections of horizontal tendon duct from said container such that said pre-cut sections of horizontal tendon duct may be deployed in the concrete receiving form.
20. The system of any preceding claim, wherein the means for deployment of reinforcement elements further comprises at least one robotic arm configured for applying ties to reinforcement elements and/or placing spacer elements and/or cutting reinforcement elements where required.
21. The system of claim 20 when dependent on claim 2, wherein the at least one robotic arm is locatable on the central beam, and preferably a plurality of robotic arms are dispersed along the central beam longitudinally such that said plurality of robotic arms may access the entirety of the concrete receiving form between adjacent yokes, preferably, the at least one robotic arm being movably mountable to the central beam via a robotic arm carriage.
22. The system of any preceding claim further comprising means for supplying concrete to the concrete receiving form.
23. The system of claim 22, wherein the means for supplying concrete comprises a hose connected to a source of concrete at a first end, said source of concrete being pumped along said hose to an outlet at the second end thereof, the hose being retained proximal its outlet by a hose carriage such that the outlet of the hose is directed towards the concrete receiving form, the hose carriage being operably attachable to one of the beams via a hose guide rail such that the hose may be moved along the guiderail to direct concrete into the concrete receiving form along its longitudinal length.
24. The system of any of preceding claim comprising a control arrangement, the control arrangement comprising a processor in operable communication with a computer readable memory means, the computer readable memory means comprising software stored thereon that when executed by the processor controls and/or synchronises movement of the various components of the means for deployment of reinforcement elements, optionally the control arrangement comprising one or more sensors configured to determine the location/positioning of the reinforcement elements and/or the various components of the means for deployment of reinforcement elements, said one or more sensors being in operable engagement with the processor and/or the computer readable memory means such that readings from said one or more sensors may aid in the control of the various components of the means for deployment of reinforcement elements.
25. A method of slip forming/jump forming a concrete structure comprising the steps of: automatically deploying vertical reinforcement members from a means for automatic deployment of reinforcement elements into a concrete receiving form configured to receive and shape concrete, the vertical reinforcement elements being secured to vertical reinforcement members of an already complete slip formed layer immediately below or secured at ground level where the layer being currently formed is a first layer, the concrete receiving form being attachable between two adjacent yokes and movable vertically with said yokes under the influence of a means for effecting vertical movement of said yokes; automatically deploying horizontal reinforcement members into the concrete receiving form from the means for automatically deployment of reinforcement elements; tying the horizontal and vertical reinforcement elements at intersections thereof using a robotic arm mountable on the at least one beam; optionally, automatically deploying vertical tendon ducts from the means for automatic deployment of reinforcement elements; optionally, automatically deploying horizontal tendon ducts from the means for automatic deployment of reinforcement elements; pouring concrete into the concrete receiving form; and once the poured concrete is at least partially set moving the yokes vertically upwards in one movement or at a constant gradual rate of movement and repeating the above steps to form a further layer, and repeating the formation of layers until a desired height is reached.