US3622072A

US3622072A - Structure installation method

Info

Publication number: US3622072A
Application number: US833406A
Authority: US
Inventors: Kentaro Matsubara; Yutaka Satoh; Yoshiro Higuchi; Shigeru Tamura; Yasuo Shimizu
Original assignee: Japan National Railways
Current assignee: Japan National Railways; Nippon Kokuyu Tetsudo
Priority date: 1968-06-20
Filing date: 1969-06-16
Publication date: 1971-11-23
Anticipated expiration: 1988-11-23

Abstract

A flexible bag is interposed between a concrete slab bearing track rails and a base structure of a railway road bed, relative to which the slab is temporarily held apart, and then fluid cement mortar is fed into the bag to infate the same and form a pliable, bag-confined mass of mortar which snugly fits the space between the slab and base structue and, upon hardening, forms a strong and firm member whereby the slab is installed on the base structure.

Description

waited @taies Patent Inventors Appl. No.

Filed Putented Assignee Priorities lrntnm Matsullmm Tokyo-to;

Vutelun Sintoh, Tokyo-to; Yosllilt'o Hlguehl, Toltyarw; Shligeru Tumum, Tokyu: Ynsuo lulmlzu. ichllmwnmhl, mll oil Jmpn 933,406

.lume 16, 1969 Nov. 23, 197B Nlppon lKollmyu Tetsudo Toliym, Japan June 20, 1968 Japan June 20, 1968, Japan, No. 43/42236 STRUCTURE lNSTAlLlLATlON METHOD l S Claims, l5 Drawing Figs.

US. Cl 23S/l, 52/744, 23S/283, 264/220 Int. CI EQulbQj/OVQ lill 3,622,072

"[50] FieldoiSearch 23S/2,1, 283; l04/l, 2; 264/220, 45; 52/744; 2 l4/220, 45

[56] References Cited y UNITED STATES PATENTS '2,875,953 3/1959 Weber etal. 238/2 3,382,815 5/1968 Higuchi et aL... l04/3 3,432,098 3/1969 Sato 238/283 3,442,222 5/l969 Olson etal l04/3 Primary Examiner- Arthur L. La Point Assistant Examiner-Richard A. Bertsch Attorneys-Robert E. Burns and Emmanuel J. Lobato ABSTRACT: A flexible bag is interposed between a concrete slab bearing track rails and a base structure of a railway road i'bed, relative to which the slab is temporarily held apart` and then fluid cement mortar is fed into the bag to infate the same and form a pliable, bag-confined mass of mortar which snugly ts the space between the slab and base structue and, upon hardening, forms a strong and rm member whereby the slab "isinsiailgqqnsh base structure.

PATENTEUNuv 23 Ism SHEET B UF 6 FIG.

FIG. I5

STRUCTURE INSTALLATION METHOD BACKGROUND OF THE INVENTION This invention relates to techniques in installing relatively heavy structures and more particularly to a new and improved method for installing an upper structure on a lower structure with a specific positional relation thereto.

One example, although by no means the only example, of such installation is the installation of concrete slabs bearing railway track rails on a base structure. In such an installation it has heretofore been necessary to use concrete forms and accompanying structures. Furthermore, such installations have heretofore required a high degree of skill. in spite of which the supported state of the upper structure has not been uniform in many cases, particularly where such support is required over a long distance.

SUMMARY OF THE INVENTION It is another object of the present invention to provide a simple installation method whereby an upper structure can be supported positively and securely on a lower structure.

Another object of the invention is to provide a method as stated above whereby the upper structure can be thus installed rapidly in uniformly supported state with relative simple equipment and without concrete forms and the necessity for high skill, the ultimate object being to reduce the cost and time of installation of such structures.

According to the present invention in one aspect thereof, briefly summarized there is provided a method as stated above wherein at least one flexible bladderlike bag is interposed between a lower structure and an upper structure held temporarily thereabove and is inflated with a hardenable fluid substance forced into the bag, whereby a pliable, bag-confined mass of the fluid substance fits intimately and firmly between the upper and lower structures and, upon hardening, constitutes a member for positively and securely supporting the upper structure on the lower structure.

According to the present invention in another aspect thereof, there is provided an installation method wherein a flexible bag filled with a hardenable fluid substance is partly interposed in the space between the upper and lower structures temporarily held at specific relative positions, and the remainder part of the bag, which is disposed outside of the space between the structures, is squeeze toward the space to compel the fluid substance therein to move into the part of the bag between the upper and lower structures.

The nature, principle, details, and utility of the invention will be more clearly apparent from the following detailed description with respect to preferred embodiments of the invention when read conjunction with the accompanying drawings, in which like parts are designated by like reference numerals.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. l is a perspective view, with parts cut away and foreshortened, indicating one example of practice embodying the invention;

FIGS. 2 and 3 are perspective views respectively showing parts of polyethylene bags for injecting mortar thereinto and for inspection for the example illustrated in F IG. l;

FIG. d is a perspective view, with parts cut away and foreshortened, indicating another example of practice of the invention;

FIGS. 5 and 6 are perspective views respectively showing parts of polyethylene bags for injecting mortar thereinto and for inspection for the example illustrated in FIG. 4;

FIG. 7 is a perspective view, with parts cut away and foreshortened, indicating still another example of practice of the invention;

FIGS. 8 and 9 are perspective views respectively showing parts of polyethylene bags for injecting mortar thereinto and for inspection for the example illustrated in FIG. '7;

FIG. I0 is a perspective view showing one example of apparatus for injecting mortar into polyethylene bags in accordance with the invention;

FIGS. 11 through I4, inclusive, are cross-sectional views indicating progressive steps in one example of practice of the invention in another aspect thereof; and

FIG. l5 is a perspective view showing one example of a second pressing device suitable for use in the method indicated in FIGS. 1l through 14, inclusive.

DETAILED DESCRIPTION In one example of practice of the invention as applied to a railway track which does not require maintenance and as illustrated in FIGS. l, 2, and 3, a concrete base structure I is provided as a lower structure and has along its center in the longitudinal direction a plurality of upright projections Ia fixed integrally to the base structure 1 at specific space intervals.

A precast concrete slab 2 for supporting the track rails thereon is to be supported on the base structure l as described hereinbelow and is provided with slot holes 2a or cutouts 2a at positions confronting corresponding projections Ia, which have dimensions such that each projection can fit loosely in the corresponding hole 2a or cutout 2a,.

The slab 2 is mounted by suspending it above the base structure l so that the projections la fit into the slot holes 2a and cutouts 2a, at specific intervals. At the same time, wedges (not shown) are inserted between the base structure l and slab 2 thereby to mount the slab 2 temporarily on the base structure with a suitable spacing therebetween. During this assembly, packing members 3 are inserted between the sides of the holes 2a or cutouts 2al and their corresponding projections la thereby to determine the relative positioning of the base structure and the slab.

The slab 2 is provided beforehand along the two lateral sides of its lower surface in the longitudinal direction thereof with two rubber mats 4. A series of polyethylene bags 5 of tubular strip shape as described hereinafter is next inserted between the lower surface of each rubber mat 4 and the upper surface of the base structure l.

One end of each bag 5 and the nearest end of the adjacent bag 5 are communicatively connected to respectively opposite open ends of a tubular box 6 made of vinyl chloride plate and provided on its upper part with a pipe fitting 6a including a valve for supplying cement mortar into the box and bags. The other end (i.e., the end opposite the end connected to a box 6) of each bag 5 is communicatively connected to an open end of a vinyl chloride box 7 closed at the other end and having at its upper part an inspection hole to which an inspection tube 7a is communicatively connected.

A feedpipe connected at one end to the discharge aperture of a cement mortar feeding hopper (not shown) is connected at the other end to each pipe fitting 6a. Each inspection tube 7a is supported substantially vertically by suitable means.

In operating the apparatus of the above described organization cement mortar which has been kneaded in a mortar mixer is introduced through the above-mentioned feeding hopper, the feedpipe, pipe fitting 6a, and box 6 into the pair of bags 5 connected to each box 6. All bags 5 are thereby filled and inflated with mortar, thereby uniformly and elastically supporting the slab along its entire length. This desired state of inflation of the bag 5 can be detected by observing that the mortar has risen within the inspection pipes 7a, whereupon the feeding of the mortar into the bags S is stopped.

Each of the feedpipes connected to the pipe fittings 6a and the inspection tubes 7a is then constricted at two places, and the hopper for feeding mortar and tube support means are removed and transferred to the succeeding installation site. When the mortar thus injected into the bags 5 begins to set and loses its viscosity, each bag 5 is transversely cut at sections in the vicinity of the boxes 6 and 7, which are then removed for circulatory reuse at another work site.

Examples of cement mortars suitable for use in accordance with the above described installation method of the invention are rapidahardening cement (also known as high early strength cement) mortars, Portland cement mortars in which accelerators have been admixed, resin mortars, and cement mortars in which reinforcing materials have been admixed in cases where high strength is required.

In another embodiment of the invention as illustrated in FIGS. 4, 5, and 6, the mutually nearest ends of adjacent polyethylene bags S are communicatively connected to the open opposite ends of a tubular box 6-1 made of vinyl chloride plate and having a mortar injecting nozzle pipe 6a,. The other end of each of these two bags S and the nearest end of the bag adjacent to said other end are communicatively connected to respective opposite, open ends of a vinyl chloride box 7-I and thereby communicatively connected to respective separate chambers formed by a partition 7a, within the box 7-1. The two chambers are respectively connected through inspection holes 7bl to inspection tubes 7c,.

The other parts of the apparatus are the same as or similar to those in the preceding example illustrated in FIGS. 1, 2, and 3 and are thereby designated by like reference numerals. The operation of the apparatus in this example is the same as that in the preceding example. Accordingly, description of the parts common to the two examples and of the operation will be omitted.

In a further embodiment of the invention as illustrated in FIGS. 7, 8, and 9, the ends of each polyethylene bag 5 are tapered in thickness and bent approximately perpendicularly upward and thus held by holding members l to form riser parts which are respectively provided with an integrally formed fcedpipe 6-2 and an integrally fonned inspection tube 7-2, which are held substantially upright. The nearest ends of adjacent bags are bonded at their lower surfaces to a common polyethylene sheet 8 by adhesive members 9, thereby being coupled by a connection structure which is made of the same material as the bags 5. Accordingly, a feature of this example is that all connection structures have pliabilty and flexibility similar to those of the main bag structures, whereby a series of several bags in the above-described connected state can be folded into a compact body which can be conveniently and easily transported, stored, and handled. The other parts of the apparatus are the same as or similar to those of the preceding examples and are accordingly designated by like reference numerals.

An example of a mortar-feeding device suitable for use in supplying cement mortar into the polyethylene bags 5 in an apparatus as, for example, that described above with reference to FIGS. I, 2, and 3, is illustrated in FIG. l0. This device comprises, essentially, a pair of laterally left and right hoppers I2 supported by horizontal top frame 13 to the four corners of which the upper ends of four support legs 1l of variable length are fixed, Additional support legs I4 are also fixed in a suspended state to the top frame I3 and, at their lower parts, rotatably support wheels for running on left and right rails (not shown) laid on the aforementioned slab 2. The lower discharge outlets of the hoppers I2 can be connected by mortar-feeding pipes 16 respectively to the aforementioned pipe fittings 6a of a pair of left and right boxes 6 for supplying mortar into the bags 5 connected thereto.

In using the mortar feeding device of the above-described organization, the wheels 15 are utilized to transport the entire device to a desired position, and then the legs ll are extended to a secure footing on the aforementioned base structure l or the ground on both sides of the slab 2 thereby to fix the hoppers l2 relative to the ground. The discharge outlets of the hoppers l2 and the pipe fittings 6a of the boxes 6 are then connected by feedpipes I6, and cement mortar supplied into the hoppers is introduced into the bags 5.

After the bags 5 connected to these boxes 6 have been filled and inflated with mortar. the feeding pipes 16 are disconnected from the pipe fittings 6a, and the legs Il are shortened und separated from the buse structure l or the ground. The

mortar-feeding device is then transferred to the succeeding mortar-feeding position.

In accordance with the present invention in another aspect thereof, as mentioned hereinbefore, a flexible bag or bladder filled with a hardenable fluid substance is inserted between a lower structure and an upper structure with a part of the bladder outside of the space between the two structures, and then this bladder part is squeezed so as to force the fluid therein toward that space and thereby to install the upper structure fixedly relative to the lower structure.

The manner in which this technique of installation may be carried out in practice will now be described with respect to a specific example of practice as illustrated in FIGS. l1 through 15, inclusive. The requirement in this example is to install a precast concrete slab 22 bearing rails 3l of a track on a concrete base structure 2l at a specific height thereabove.

The slab 22 is first positioned and temporarily held above the base structure 2l at the required height thereabove by means such as wedges (not shown) inserted between the slab and a precast concrete bearing pad 23 temporarily placed on the base structure 2l. A rubber mat 24 is secured to the lower surface of the slab 22 in a position to face the bearing pad 23. A timber pad or block 26 is temporarily placed on the base structure 2l to support a first pressing device 27 in a position outside of the laterally outer edge of the slab 22.

A polyethylene bag 25 filled with cement mortar in fluid state is inserted partly between the base structure 2l and the slab 22 so that a part of the bag projects outwardly from the lateral edge part of the slab 22. The outer part of the bag 25 thus projecting outwardly is clamped between an

upper plate

27b and 27a of the first pressing device 27, which is essentially of dihedral form comprising the upper and

lower plates

27b and 27a hinged along a line 27C of intersection.

In addition to the first pressing device 27, use is made of a second pressing device 28 having a channelshaped attachment member 28a comprising an upper flange 28a a lower flange 28413, and a web joining these flanges. This attachment member 28a is adapted to engage with the lateral edge part ofthe slab 22 and is held in the engaged state by a pin 29 passed through a pin hole 28a2 drilled through the upper flange 28al near the free edge thereof. The pin 29 is chained by a chain 30 to a part ofthe upper flange 28aI to prevent loss thereof.

The free edge of the lower flange 28a;i is hinged (28C) therealong to one edge of a pressing plate 28h. A support member 28d is fixed at its lower part to an edge of the pressing plate 28h parallelly opposite the hinged edge and supports at its upper part a horizontal force-applying member 28e.

In the installation procedure, the attachment member 28a is fitted onto and engaged with the laterally outer edge part of the slab 22, and then the pin 29 is inserted through the pinhole 28a2 and caused to catch against a shoulder 22a of the slab. The free or distal end of the pressing plate 28h is placed in contact with the upper part of the bag 25 at a part thereof in the vicinity of the laterally outer edge of the slab 22.

Then, after the bag 25 and the first and second

pressing devices

27 and 28 have been set in place as indicated in FIG. I1, a force such as that due to a weight of a specific weight value is applied to the upper plate 27b of the first pressing device 27 thereby to force this upper plate toward the lower plate 27a as indicated in FIG. l2. Consequently, the mortar within the outwardly projecting part of the bag 25 is squeezed toward the part ofthe bag interior directly below the slab 22.

Then, as indicated in FIG. 13, a weight of specific weight value (not shown) is placed on the force-applying member 28e of the second pressing device 28 to cause the pressing plate 28b to press downwardly with a rotational stroke about the hinged edge 28C on the bag 25. As a result, the bag directly below the slab 22 is forcibly inflated by the mortar therewithin thus pressurized and thereby firmly supports the slab on the bearing pad 23. At the same time. the free or dislul edge of the pressing plate 28h cuts off the outwardly projecting purt ofthe bag 25.

Then, when the mortar in the bag 25 hardens, the first pressing device 27 is removed together with the cut off part of the bag, At the same time, the pin 29 is extracted, and the channel-shaped attachment member 23a of the second pressing device 28 is disengaged from the edge part of the slab 22 thereby to disconnect the pressing device 2B from the installed structures. The two pressing devices 2'7 and 28 can then be transferred to another work position.

For the mortar used in the bag 25, any of the aforemen tioned mortars suitable for use in the examples described with reference to FIGS. l through l0 can be used.

lt should be understood, of course, that the foregoing disclosure relates to only preferred embodiments of the invention and that it is intended to cover all changes and modifications of the examples of the invention herein chosen for the purposes of the disclosure, which do not constitute departures from the spirit and scope of the invention.

We claim:

l. A method of installation of an upper structure on and in a specific position relative to a lower base structure, which comprises, in combination, the steps of temporarily holding said upper structure immovably in said position; inserting a resilient plate under said upper structure thereby to establish an elasticity between said upper structure and base structure; interposing a flexible bladderlilte bag between said resilient plate and base structure to form a uniforifn support layer between said structures, said bag containing a hardenable fluid substance therein and being provided with a portion projecting outward of said upper structure; squeezing said bag at said projecting portion thereof so as to compel said fluid substance to be squeezed toward part of the bag under said upper structure thereby to inflate said part of the bag and form a pli able, bag-confined mass of the fluid substance in firm contact with said resilient plate and lower base structure; and causing said fluid substance to harden thereby to cause the upper structure to be supported firmly on the lower structure through said resilient plate and said mass of the substance thus interposed and hardened therebetween.

2. A method of installation as set forth in claim l. in which said squeezing is carried out in two steps comprising a first 4step including the pressing of a first device for applying pressure to an outermost portion of said projecting bag portion, and a second step including the pressing of a second device for applying pressure to an inner portion of said projecting bag portion to urge said hardenable fluid within said projecting portion to a position between said resilient plate and base.

3. A method of installation as set forth in claim l, in which said step of inserting a resilient plate is performed by placing a rubber plate beneath said upper structure, and said step of interposing a flexible bag between said plate and base is performed by disposing a synthetic resin bag therebetween.

4. A method of installation as set forth in claim l, further comprising the step of selecting said hardenable fluid sub stance from the group consisting of rapid hardening cement mortars, Portland cement mortars having an accelerator mixed therein, resin mortars, and cement mortars having reinforced materials mixed therein.

5. A method of installation of an upper structure on and in a specic position relative to a lower base structure, which comprises the steps of temporarily holding said upper structure immovably in said position; interposing a flexible bladderlike bag between said upper sn'ucture and base structure to form a uniform support layer between said structures, said bag con` taining a hardenable fluid substance therein and being provided with a portion projecting outward of said upper structure; squeezing said bag at said projecting portion thereof so as to compel said fluid substance to be squeezed toward part of the bag and form a pliable, bag-confined mass of the fluid substance in rm contact with said upper and lower structures; and causing said fluid substance to harden thereby to cause the upper structure to be supported firmly on the lower structure through said bag-confined mass thus interposed and hardened therebetween; m n

Claims

1. A method of installation of an upper structure on and in a specific position relative to a lower base structure, which comprises, in combination, the steps of temporarily holding said upper structure immovably in said position; inserting a resilient plate under said upper structure thereby to establish an elasticity between said upper structure and base structure; interposing a flexible bladderlike bag between said resilient plate and base structure to form a uniform support layer between said structures, said bag containing a hardenable fluid substance therein and being provided with a portion projecting outward of said upper structure; squeezing said bag at said projecting portion thereof so as to compel said fluid substance to be squeezed toward part of the bag under said upper structure thereby to inflate said part of the bag and form a pliable, bagconfined mass of the fluid substance in firm contact with said resilient plate and lower base structure; and causing said fLuid substance to harden thereby to cause the upper structure to be supported firmly on the lower structure through said resilient plate and said mass of the substance thus interposed and hardened therebetween.

2. A method of installation as set forth in claim 1, in which said squeezing is carried out in two steps comprising a first step including the pressing of a first device for applying pressure to an outermost portion of said projecting bag portion, and a second step including the pressing of a second device for applying pressure to an inner portion of said projecting bag portion to urge said hardenable fluid within said projecting portion to a position between said resilient plate and base.

3. A method of installation as set forth in claim 1, in which said step of inserting a resilient plate is performed by placing a rubber plate beneath said upper structure, and said step of interposing a flexible bag between said plate and base is performed by disposing a synthetic resin bag therebetween.

4. A method of installation as set forth in claim 1, further comprising the step of selecting said hardenable fluid substance from the group consisting of rapid hardening cement mortars, Portland cement mortars having an accelerator mixed therein, resin mortars, and cement mortars having reinforced materials mixed therein.

5. A method of installation of an upper structure on and in a specific position relative to a lower base structure, which comprises the steps of temporarily holding said upper structure immovably in said position; interposing a flexible bladderlike bag between said upper structure and base structure to form a uniform support layer between said structures, said bag containing a hardenable fluid substance therein and being provided with a portion projecting outward of said upper structure; squeezing said bag at said projecting portion thereof so as to compel said fluid substance to be squeezed toward part of the bag under said upper structure thereby to inflate said part of the bag and form a pliable, bag-confined mass of the fluid substance in firm contact with said upper and lower structures; and causing said fluid substance to harden thereby to cause the upper structure to be supported firmly on the lower structure through said bag-confined mass thus interposed and hardened therebetween.