US3779678A

US3779678A - Apparatus for constructing concrete walls

Info

Publication number: US3779678A
Application number: US00113967A
Authority: US
Inventors: H Scheller
Original assignee: Research Cottrell Inc
Current assignee: Research Cottrell Inc
Priority date: 1971-02-09
Filing date: 1971-02-09
Publication date: 1973-12-18
Anticipated expiration: 1990-12-18
Also published as: CA984584A; FR2126669A5; JPS5216335B1; IT945111B; BE773131A

Abstract

In an apparatus for constructing a high-rising, poured concrete wall or shape, pairs of spaced-apart, upright supports are preliminarily mounted on a foundation and then detachably attached to both sides of at least a partially hardened level of concrete wall and at intervals along the length of the wall for repeated, upward, step-wise use as the wall is being formed; a plurality of carriages are mounted on adjacent supports along both sides of the wall for continuous upward movement as the wall is being cast, and adjustable concrete shaping assemblies are mounted on the carriages each assembly opposing a similar assembly to define a continuous mold into which new concrete is poured on top of previously poured concrete to form the wall. The method of constructing such a wall, by repeated, step-wise use of upright supports attached to lower sections of partially hardened concrete, and said supporting mounting a plurality of movable carriages, each holding a concrete shaping assembly, and pouring concrete into the assemblies along the entire length of the wall as the assemblies move continuously upwardly in unison on the supports.

Description

United States Patent [191 Scheller 1 APPARATUS FOR CONSTRUCTING CONCRETE WALLS Herman Scheller, Eaton, C010.

[73] Assignee: Research-Cottrell, Tnc., Bridgewater Township, NJ.

22 Filed: Feb. 9, 1971 21 Appl. No.: 113,967

Related U.S. Application Data [63] Continuation-impart of Serv No. 856,326, Sept. 9,

1969, abandoned.

[75] Inventor:

[52] U.S. Cl; 425/65, 52/222, 425/D1G. 126 [51] Int. Cl. 1329c 23/00 [58] Field of Search 425/DIG. 26, 63,

[ Dec. 18,1973

Primary Examiner-1 1. A. Kilby, Jr. Attorney-Harold S. OBrien, Jr.

[5 7] ABSTRACT In an apparatus for constructing a high-rising, poured concrete wall or shape, pairs of spaced-apart, upright supports are preliminarily mounted on a foundation 1 and then detachably attached to both sides of at least a partially hardened level of concrete wall and at intervals along the length of the wall for repeated, upward, step-wise use as the wall is being formed; a plurality of carriages are mounted on adjacent supports along both sides of the wall for continuous upward movement as the wall is being cast, and adjustable concrete shaping assemblies are mounted on the carriages each assembly opposing a similar assembly to define a continuous mold into which new concrete is poured on top of previously poured concrete to form the wall. The method of constructing such a wall, by repeated, step-wise use of upright supports attached to lower sections of partially hardened concrete, and said supporting mounting a plurality of movable carriages, each holding a concrete shaping assembly, and pouring concrete into the assemblies along the entire length of the wall as the assemblies move continuously upwardly in unison on the supports.

12 Claims, 12 Drawing Figures HULL! in n l u u n n n l n n 11 ii I: n n

in u u n n PATENTEUHEC 18 ms 3,779,678 I SHEET 2 0; 5

If H [I ll PAIENIEMEmama 3,779,678 saw u 0F 5 INVENTOR. Hermon Scheller ATTORN EY.

PATENIEHHEC 18 I975 SHEET 5 OF 5 INVENTOR. Hermon Schelier ATTORNEY.

APPARATUS FOR CONSTRUCTING CONCRETE WALLS BACKGROUND OF THE INVENTION This application is a continuation-in-part application of my prior, co-pending application Ser. No. 856,326 filed on Sept. 9, 1969, now abandoned.

Modern concrete wall casting techniques frequently utilize pairs of spaced-apart, shaping forms held in position by various types of movable supports, the concrete being poured between the forms and on top of the section of wall poured earlier and partially set. After the last poured concrete has at least partially set, the forms are removed and relocated above the former position and then the procedure is repeated until the wall is completed.

There are several known ways in which the forms may be supported and moved into new positions as the wall progresses and it is highly desirable that this procedure be accomplished as efficiently as possible. External scaffolding may be erected and through the use of blocks and tackle attached to a higher level of the scaffolding, the forms may be relocated and so supported until the poured concrete has set. The disadvantages of this procedure are; scaffolding is both expensive and time consuming to erect and dismantle, and is especially inefficient when the height exceeds 100 feet. Another procedure utilizes substantial, vertical rods placed in the wall as it is formed, carriages carrying the shaping forms being supported by the rods. The carriages are raised on the rods by a series of jacks as the wall is formed. Use of such vertical rods has the disadvantage that it tends to weaken the wall along the entire length of the rod.

A further procedure is that disclosed in US. Pat. No. 3,472,477 to P. Juhl which teaches the use of a series of upright support brackets spaced along and attached by bolts to sections of set concrete in the wall being formed, the brackets supporting the concrete shaping forms at their tops and the brackets being lifted at intervals by blocks and tackle. A limitation of the apparatus of this invention is that upward movement of the brackets is intermittent and must await setting of the section or level last poured.

In addition to the disadvantages and limitations of the prior art techniques described above, many such techniques are unable to readily shape the concrete being poured, such, as for example, is required in constructing. the veil of a cooling tower where the diameter of the veil varies from top to bottom in following the shape of a hyperboloid of revolution.

SUMMARY OF THE INVENTION This invention provides a new and improved apparatus and method for efficient casting of shaped concrete walls and, in the exemplary embodiment, includes a plurality of pairs of spaced-apart, upright supports extending from the foundation initially and then attached to opposing sides of the wall being formed along the entire length of the wall, sections of each support being detachable at the bottom of the support and from the wall at intervals and re-attached at the upper end of the support to form a continuously advancing support as the wall is formed. Mounted on adjacent supports on each side of the wall for upward movement are a plurality of carriages which extend along or around the entire length of thewall and carry the concrete shaping forms upwardly as the wall is formed. Each form comprises, in the preferred embodiment, an extendible, flexible sheet backed by lateral supports with means for varying the position and effective length of each form. The preferred method of this invention provides for upward movement of all of the carriages in unison at a selected rate on the supports and the continuous flow of concrete into the forms so that as concrete sets adjacent the bottom of the forms, the forms are moved upwardly to support a new level. At intervals, and without interrupting the upward movement of the forms, a section of each support is detached from the bottom of the support and from the wall and re-attached to the top of the support above the carriage to provide a continuous track. The construction of the forms permits selective alteration of the shape of the perimeter of the wall being cast and the wall thickness.

Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective, stylized view of the base portion of a cooling tower veil being formed by the casting apparatus of this invention;

FIG. 2 is a vertical section of the apparatus showing the wall being cast and the preferred form of supports and carriage;

FIG. 3 is a top view of the apparatus shown in FIG.

FIG. 4 is an enlarged, fragmentary side elevation of a form or shaping assembly;

FIG. 5 is an enlarged, fragmentary plan view ofa portion of one carriage;

FIG. 6 is an enlarged, elevation view of one form of the carriage elevating and retaining mechanism;

FIG. 7 is an enlarged, horizontal section of the end portions of two form assemblies with the adjacent support;

FIG. 8 is a side elevation view of one part of theform assembly;

FIG. 9 is a rear elevation of the sheet portion of the form assembly;

FIG. 10 is a fragmentary plan view of a carriage with a section through the concrete wall;

FIG. 11 is a side elevation view of a modified form of the carriage; and

FIG. 12 is a fragmentary horizontal sectional view of a modified form of the form assembly and related apparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred embodiment of the apparatus and method of this invention is set forth herein, for illustrative purposes, in connection with the construction of a concrete veil or outside wall of a natural draft cooling tower, which frequently rises 450 feet above the ground and has a diameter of 350 feet at ground level. In such construction, the round concrete wall decreases in diameter as it rises until narrow section or throat is reached, and then increases in diameter toward the top to form the hyperbolic shape. However, it should be understood that this invention is equally applicable in construction of other shapes, such as chimneys. As illustrated in FIG. 1, the tower veil or wall 10 has an outer surface 12 and an inner surface 14, and

a series of carriages 18 located entirely around the top of the wall.

During the initial construction of a cooling tower or chimney and after the ground foundation has been laid, pairs of opposed, spaced-apart, generally vertical supports or I-I-beams 20 are anchored on the foundation, or on a raised platform or lintel above the ground from which the circular wall is constructed, in the case of a natural draft cooling tower of the Hamon-Cottrell, Inc. design. Each support 20, not shown in FIG. 1 but located at each carriage 18, is 30 feet long and is composed of several sections 22 of structural steel H- Beams, typically 8 5-% in. size, each about 10 feet in length, which are jointed at their ends by bolted plates 24 as shown in FIG. 2. The beams of each pair are separated from each other by a distance which will generally be the thickness of the wall 10 being formed, which at the base ofa tower is about 30 inches. The beams are spaced apart, as desired, as best shown in FIG. 11, by a plurality of horizontal spacers or internally threaded inserts 26 attached to the beam flanges 20a by bolts 260 before concrete is poured between the beams and other assembly. Each pair of beams 20 are separated by about 10 feet from similar pairs around the wall so that the beams are located at spaced intervals completely along both the inner and outer wall surfaces 12, 14. Beam sections 22 are staggered on opposing beams for greater strength as shown in FIG. 2. As the concrete is poured between the beams and the wall increases in height, a lower section of each beam is detached from the side of the wall 10 by removing bolts 26a from the spacers 26, leaving the spacers in the wall, and separating the rivet plates 24, then the section is attached to the top of the same beam and attached to an opposing section by new spacers. As the concrete cures, the lower sections of each support held tightly against the wall surfaces easily support the carriages 18 and other structures mounted on them. The beam sections 22 may be lifted into new position by a simple block and tackle or other lifting means mounted on the carriages 18. The beams 20 are also provided with spaced apart lugs 30 (FIG. 2) permanently affixed to the outer flange 20b of each beam for a purpose later described. In this way, only three or four beam sections are required to form each support and the supports 20 are independent of the ground or any other structure except the wall 10 itself.

A plurality of carriages 18, shown in FIGS. 1, 2, l and 11, are separately mounted for vertical movement on beams 20 and adjacent carriages support there between concrete form'assemblies 16 which shape the surfaces of the wall being formed. Additionally, as shown on FIG. 2, the carriages provide a working platform for men and equipment which extends entirely around the wall being formed.

Each carriage 18, reference being made to FIGS. 2,4, and 6, includes a pair of similar frames 19 composed of several common structural beams welded and bolted together to form a strong, unitary structure. In detail and as shown in FIG. 2, each frame includes a top, horizontal channel 34 welded to vertical channel 32, which, in turn, is welded to lower horizontal channel 38. Vertical channel 40 is welded to

channels

34 and 38 and angled channel 42 supports the outer end of beam 34. Two adjacent frames 19, one being constructed opposite hand, are jointed together to form each carriage 18 mounted on a beam by bolted connector plates 33 (FIG. 2) and also by a pair of threaded rods 132 and nuts 134 (FIG. 5), the inner rod 132 being bolted to a pair of beams 46 which, in turn, are bolted to adjacent frame beams 34 by bolts 48 and nuts 50 (FIG. 2). By adjustment of the threaded rod 132 (closest to the wall 10), beams 46 can be made to pivot slightly in relation to frames 19 and thereby provide adjustment in the concrete shaping assemblies described hereafter.

Wheels

110, 112 and 114 (FIG. 2) are attached to beam 32 of each frame 18 by short axles (not shown) and ride against opposing sides of the two outer flanges 20b of beam 20 holding the carriage against the beam.

A hydraulic jack 118 (FIG. 6) is attached to both frame beams 34 in each carriage through pin connection 116 and exerts upward thrust against the carriage when hydraulic pressure is supplied through flexible hose 120 and extendable pawl 122 is engaged with cleat 30 on beam 20. A follower pawl 124 is pivotly mounted on pin 126 extending through frame beams 32 and has a weighted portion to assure proper engagement of tooth 128 with lugs 30. Normally, the carriages progress in an upward direction by extension of pawl 122 until tooth 128 engages a higher lug 30 followed by withdrawal of pawl 122 for relocation against a higher lug 30, and repeating. However, if necessary, a carriage can be lowered by extending hydraulic jack 118 so that the load carried by follower pawl 124 is now transferred to extendable pawl 122 and engaged cleat 30, and slowly retracting the jack thus allowing the carriage to settle and follower pawl 124 to engage in the next lower cleat 30. These steps can then be repeated. A working scaffold is formed by planks 36 resting on beams 34 of adjacent carriages and an outer rail 44 between which ropes or planks may be placed. The scaffolding may include other equipment not shown such as concrete buckets and tracks, and hoists and block and tackle.

Concrete shaping form assemblies 16, generally shown in FIGS. 2, 4, and 9, span the distance between adjacent carriages 18 on both sides of the wall being formed and form the sides of the mold into which fresh concrete is poured. Each form assembly 16 includes a flexible sheet 64, two end rollers 56 (FIG. 9) lateral, telescoping, intermeshed finger-like elements 70 and 74 (FIG. 4) and supporting structure. Flexible sheet 64 may be light gauge steel, No. 20 Ga. for example, or any material suitable for providing a flexible and impervious casting surface.

Telescoping elements

70 and 74 provide lateral support for sheet 64 and may be formed from wood 2X4s.

The end rollers 56 and supporting structure, shown generally in FIGS. 5, 7 and 9, are lengths of pipe with capped ends vertically supported at their ends for limited rotational movement by pins 58 which extend into recesses 58a formed in the ends of each roller. Pins 58 are welded to the inner ends of upper and lower supports 46 so suggested by the location of the assembly shown in FIG. 5. Preferrably, recesses 58a are placed off center so that they define an eccentric pivotal axis, as indicated in FIG. 7, so that when the rollers are turned, the sheet 66 may be brought into tight contact with the flanges 20a of each support beam 20.

Attached to the ends of each roller are

plates

52 and 54 which help support the sheet 64 and a pocket member 60 as shown in FIGS. 7 and 8. The pocket member 60 has a plurality of horizontally spaced pockets 62 which receive the ends of

finger elements

70, 74.

With reference to FIGS. 2, 3 and 7, sheet 64 has an inner face or casting surface 66 against which the concrete is poured and on the reverse or outer side is supported by generally parallel, vertically spaced finger elements 70 held in pockets 62 by retaining pin 72 shown in FIG. 4. Meshed with the'first set of finger elements 70 is a second set of finger elements 74 similarly mounted on a frame of the adjacent carriage. Generally the length of the

fingers

70 and 74 will be equal to at least half of the maximum contemplated distance between the I-I-beams 20, and less than the contemplated maximum as shown in FIG. 4.

To support the

fingers

70, 74 against the outward force developed on the sheet 64 when concrete is poured between opposing sheets, a pair of horizontal I-I-beams 45 are placed between

vertical channels

32 and 40 of adjacent frames as shown in FIG. 2. Bottom beam 45 may reston channel 38 while upper beam 45 may be supported by portions of the jacking mechanism or on flanges mounted on

channels

32, 40. Preferrably, beams 45 are mounted on the carriages so that the beams will slide on the frames and extend beyond adjacent carriages, as shown in FIG. 3, when the carriages are brought closer to each other, as when the diameter of the wall decreases. A vertical wedge 76 is driven between the two horizontal beams 45 and the figure 70, 74, as shown in FIG. 3, to fully support sheet 64 throughout its length.

Each flexible sheet 64 isprovided with apparatus shown in FIG. 9 to control its length and tension its inner surface 66. A pair of rigid end members 78 are secured to the ends of sheet 64 by bolts 80 and links 85 are connected in apertures 82 in members 78 and to chain yokes 86. The chain 86 further connects to link 87 and, on the left hand side, to a heavy spring 90, a chain 92, and then to a conventional ratchet tensioning mechanism 96. On the right hand side, chain 88 connects to chain 98 and hook 100 whereby the actuation of handle 102 draws hooks 94 and 100 together thereby tensioning the spring 90 and pulling opposite ends of the sheets 64 towards each other to place the sheet 64 under tension.

Referring now to FIG. 7, when tension is applied to the sheets 64, the ends of the sheets 64 move in the direction of arrows 104 thereby causing the associated roller 56to rotate in a direction indicated by arrows 106. As a result of the eccentric mounting of the roller 56, it will be seen that such rotation will bring sheets 64 into tight engagement with the adjacent flanges of the H-beam so as to close any gaps between form casting surfaces 66 and flange of beam 20. Thus, a generally continuous and tight casting surface is obtained.

While FIG. 7 depicts an irregular, ridged casting surface due to relative position of the form surfaces 66 and beam 20, it will be appreciated that an essentially smooth casting surface, as shown on the inner wall of FIG. 3, can be provided merely by changing position of the pivotal axes of rollers 56. Requirements of various structures determine whether a ridged or smooth wall surface is to be cast. For example, in cooling tower construction, the outer wall surface 12 is generally ridged and the inner wall surface 14 is generally smooth, as shown in FIG. 3. The plurality of vertical ribs thus formed on the completed tower serve to induce air turbulance, thus enhancing heat transfer.

The apparatus for tensioning the sheets 66, shown in FIG. 9, will also provide adjustments of the length of the sheets. By initially forming sheet 64 of sufficient length to accommodate the maximum possible spacing of the H-beams 20 contemplated in any construction, the effective length can be reduced by adjustment of

chains

92 and 98. Thus, as in the case of a cooling tower, at the bottom and top, most of the total suface 66 of the sheet may be used as a form surface while at the tower throat, significantly less than the total surface 66 of the sheet 64 may be used.

FIGS. 10, 11 and 12 illustrate alternate embodiments for carriage propulsion and form assembly. In the cutaway portion of beam 32 shown in FIG. 11, a hydraulic jack 118 is fitted with improved pawl means consisting of reciprocating bar and a pivoted pawl 142 which is spring loaded (spring not shown) to insure positive engagement between pawl 142 and lugs 30. Further, wheels 144, which are mounted on a plate (not shown) which extends between adjacent beams 32, are in rolling contact with reciprocating bar 140 to resist lateral forces on bar 140 and prevent disengagement between pawl 142 and lugs 30. In addition, a follower pawl 124 welded to short length of pipe 125, which in turn is mounted for rotation on a shaft 125a extending between beams 32, engages lugs 30 and is held in engagement by spring 146.

FIG. 12 shows a modification of the form assembly described previously and is particularly useful where a smooth surface and an opposite ribbed wall surface are desired. Two forms of fixed end supports and 152 (shown on the left side of FIG. 12) are used in conjunction with movable roller end supports 154 on the other side, the latter being the same as previously described roller support 56. In this arrangement, flexible sheet 64 is attached by welding or other means to fixed end supports 150 and 152 and then wrapped around the roller end supports 154 and tensioned by pulling in the direction of arrows 156. As each sheet 64 has only one free end 158, a single tensioning mechanism can be used to tighten the sheet. The fixed form supports 150 or 152 of two adjacent assemblies may be attached to the same carriage on alternating H beam supports 20A around the periphery of the structure so that the free ends 158 are now opposing at alternating beams and may be pulled taunt by a single tensioning device. Further, it will be seen that fixed end support 152 is adapted for casting smooth surface while fixed end support 150 will produce a vertically ribbed surface. Also, that roller form supports 154 produce both smooth and ribbed surfaces depending on position of pin 58 in relation to beam 20.

HIGH-RISE CONCRETE WALL FORMING In the case of a moderately sized natural draft cooling tower, the base diameter might typically be 350 ft., the height 450 ft., and a wall thickness of 30 in. at the base which gradually diminishes to 7 inches about 100 ft. from the ground. In addition, the wall surfaces are designed to define hyperbolic surfaces of revolution, that is, the tower will have its largest diameter at the base gradually decreasing in diameter with height until a throat section is reached at approximately 65 percent of the final height and then increasing in diameter until the top is reached. At the throat section the diameter will be approximately 65 percent of the base diameter and at the top it will be approximately 75 percent of the base diameter.

To build such a tower, a circular lintel, defining the base of the tower, is first constructed on post supports set in suitable foundations in the ground. Next, pairs of support beams 20 are braced in a generally vertical position against inner and outer peripheries of the lintel at approximately 10 ft. intervals completely encircling both sides of the lintel. Threaded spacers 26 and bolts 26a are also installed between pairs of beams thus determining wall thickness. Carriages 18 may then be installed on supports 20, and adjustable forms 16 are attached to the carriages forming a continuous mold around and on top of the lintel. After reinforcing materials have been added, the first section of wall is poured and allowed to harden securely embedding the lowermost spacers 26 in concrete. The forms are then jumped upward nearly full form height (approximately 4 or 5 ft.) to cast the next course which will embed additional spacers 26 in concrete. The forms are jumped by operation of the hydraulic jacking mechanism and, by virtue of such mechanism, essentially the entire casting form for the tower can be raised in increments of approximately 4 inches (as set by spacing of cleats After several jump castings are made, the lower ends of support beams 20 become very firmly attached to the wall by a number of embedded spacers 26. Thus, support beams 20 now provide strong cantilever means to support the carriages, casting forms, and a working platform as the wall rises.

In casting the initial courses of the wall an ordinary general crane is used to raise the plastic concrete from the ground to the working scaffold where it is distributed by wheeled carts to the forms around the periphery of the structure. It will be appreciated that several cranes may be used simultaneously so that such a large structure can be cast at a reasonable rate. When the structure height exceeds reach of the cranes, a number of small booms with pulley means are attached to selected carriages spaced around the wall. These booms now provide the means to transport plastic concrete and other materials to the work area. The concrete is raised in buckets (approximately k cu. yd. capacity) by cables running over the pulleys on said booms and returning to hoisting engines on the ground. Thus, the necessity for using a large tower crane is avoided and the work can progress much more quickly and safely than with such a crane.

As the structure progresses skyward, the lowermost section 22 of support beams 20 are unbolted from the wall and attached to the uppermost section by rivet plates 24. These splices are made alternately in the paired beam members to avoid any possible weak spot such as would occur if both joints occurred at the same elevation. Also to accommodate the required shape of the structure, the spacing between paired beams 20 is gradually adjusted by spacers 26 and the beam sections are directed inwardly or outwardly according to preset coordinates for each particular elevation. Further, the tensioning means 96 on the adjustable form sections is operated to allow the flexible form member to contract or expand as required by a particular cross sectional circumference and diameter.

The improved apparatus can also be used for an advantageous casting method known as slip forming." In this method the forms are essentially continuously moved upwards in smaller steps (approximately 4 inches) as the plastic concrete is continuously supplied and is progressively setting with varying degrees of hardness. Weather permitting, it is possible to advance the forms upwards at a rate of approximately 1 ft. per hour, thus accomplishing a 7 or 8 hour wall height in a normal 8 hour shift. This provides distinct advantage over "jump form casting methods" such as required with the .Iuhl apparatus. In jump form casting the wall can only be formed to the height of the forms (about 4 ft.) each day and then must be allowed to harden overnight before advancing the forms.

From the foregoing, it will be appreciated that the invention provides both new and improved concrete casting apparatus as well as an improved method that is particularly suitable for casting a continuous wall of varying dimensions such as those in cooling towers. The assemblage is operative without the use of external scaffolding and does not rely on vertically disposed rods to be retained within the concrete wall being poured which could weaken the same. The unique arrangement whereby the length of the form surface of any form providing means can be varied together with the provision of telescoping support means therefor provides for relatively simple adjustment of the forms as a change in periphery is required. Further the sup port beams and self-propelled carriages provide a form support system and transportable working area which facilitate the work by virtue of the structural integrity created.

The new construction method afforded by the invention, eliminates necessity for special and expensive tower cranes to transport plastic material to the work area and also provides great savings in manpower and calendar time to construct large high-rise concrete walls. Using the apparatus and method disclosed it is now possible to build complex large structures to virtually any height more economically, faster, and with greater safety than with other hither to known apparatus.

Having described a preferred embodiment and use of my invention, I do not wish to be restricted to the details set forth, but rather, to have the same construed according to the following claims.

I claim:

1. Apparatus for forming a concrete wall comprising a. a plurality of generally vertical supports spaced apart along both sides of the wall being formed, each support being located opposite to another support on the other side of the wall and detachable connected to said opposing support by a plurality of spacers some of which are contained in the wall previously fonned, each support consisting of separate segments detachably joined together at their ends, and the lower portion of each support being held contiguous the surface of the wall previously formed by said spacers while the upper portion extends above the portion of the wall previously formed;

b. a carriage mounted for vertical movement along each support with lifting means mounted on and carried thereby for engaging contact along the length of each support section as the wall is formed for advancing the carriage upwardly along the supports as the wall is formed;

c. a plurality of concrete casting assemblies located along and on both sides of the wall being formed adjacent its top, each assembly supported at its ends by two carriages on adjacent supports and each assembly having a generally vertical casting surface extending between the supports so that the assemblies together define a continuous mold extending completely around the top of the wall into which concrete is poured, whereby as the concrete hardens the carriages and assemblies are moved upwardly on the supports to form a new level of wall and, at intervals, the support segments are detached from the bottom of each support and attached to the top to provide a continuous track for the carriages; and

(1. wherein each support segment comprises an H- beam with the inner side flange being contiguous with a surface of the wall being formed and the outer flange being generally parallel to but spaced apart from the wall, and a plurality of rollers attached to each carriage and mounted for movement along the outer flange of the adjacent beam, at least two rollers located on opposing sides of the outer flange and on opposite sides of the beam to allow the carriage to move vertically on the support but to prevent the carriage from separating from the beam.

2. Apparatus for forming a concrete wall comprising a. a plurality of generally vertical supports spaced apart along both sides of the wall being formed, each support being located opposite to another support on the other side of the wall and detachably connected to said opposing support by a plurality of spacers some of which are contained in the wall previously formed, each support consisting of separate segments detachably joined together at their ends, and the lower portion of each support being held contiguous the surface of the wall previously formed by said spacers while the upper portion extends above the portion of the wall previously formed, A b. a carriage mounted on each support with means for advancing the carriage upwardly along the supports as the wall is formed,

. a plurality of concrete casting assemblies located along and on both sides of the wall being formed adjacent its top, each assembly supported at its ends by two carriages on adjacent supports and each assembly having a generally vertical casting surface extending between the supports so that the assemblies together define a continuous mold extending completely around the top of the wall into which concrete is poured, whereby as the concrete hardens the carriages and assemblies are moved upwardly on the supports to form a new level of wall and, at intervals, support segments are detached from the bottom of each support and attached to the top to provide a continuous track for the carriages, and

d. the assembly casting surface comprises the inner surface of a generally horizontal, flexible sheet whose effective length may be varied by advancing at least one end of said sheet around a roll, said roll being supported by the assembly in generally an upright position adjacent one vertical support.

3. The apparatus as defined in claim 2 further including a plurality of generally horizontal braces mounted on the assembly and position contiguous the outer surface of the flexible sheet to support the sheet while the concrete is setting against the inner surface of said sheet.

4. The apparatus as defined in claim 3 wherein said assembly roll is mounted on an eccentric axis on the assembly so that when the flexible sheet is advanced around the roll and the roll rotates, the inner surface of the sheet is drawn into contact against the adjacent support thereby providing a continuous casting surface.

5. The apparatus as defined in claim 4 further including means attached to each carriage outward from the wall for providing a continuous, level working platform around the top of the wall from which concrete may be poured into the assembly.

6. The apparatus as defined in claim 5 wherein each support segment comprises an H-beam with the inner side flange being contiguous with a surface of the wall being formed and the outer flange being generally parallel to but spaced apart from the wall, and a plurality of rollers attached to each carriage and mounted for movement along the outer flange of the adjacent beam, at least two rollers located on opposing sides of the outer flange and on opposite sides of the beam to allow the carriage to move vertically on the support but to prevent the carriage from separating from the beam.

7. The apparatus as defined in claim 6 wherein the means for advancing a carriage upwardly along a beam comprises a series of spaced apart lugs attached to the outer flange of the beam, a jack attached on one end to the carriage and engaged against a lug at the other end, and a catch attached to the carriage for intermittent engagement with a lug whereby upon activation of the jack the carriage is raised until the catch engages the next higher lug.

8. Apparatus for casting a concrete wall comprising a pair of assemblies arranged in spaced relation with each of said assemblies including:

a. at least two vertically extending, elongated, horizontally spaced structural members each having I. a vertical guide way and 2. vertically extending grip means;

b. means defining a form surface extending between said structural members, said form defining means being generally horizontally extendable,

c. means at each end of said form defining means and engaging the vertical guide way of the adjacent structural member for guiding said form defining means for movement in a vertical direction along said guide ways;

d. a pair ofjack means, one at each end of said form defining means, for selectively engaging said vertically extending grip means and for advancing said form defining means vertically upwardly on said structural members,

e. means associated with at least one of said form defining means and said structural members for maintaining said form defining means at a desired vertical location on said structural members and f. said apparatus further including means for holding corresponding ones of the structural members of each pair of each assembly in spaced relation whereby the form defining means of the pair of assemblies define a concrete receiving space.

9. An assembly for casting concrete according to claim 8 wherein said form defining means comprises a sheet of material and horizontally telescoping means supporting said sheet.

10. A concrete casting assembly according to claim 9 wherein said sheet is trained about eccentrically mounted rollers adjacent the ends of said form providing means and further including means for placing said sheet under tension.

11. An apparatus for casting concrete walls comprising a plurality of assemblies arranged in a first and a second spaced apart closed configuration, each of the assemblies comprising:

a. at least two horizontally spaced, vertically extending I-beams, each having cleats mounted thereon;

b. at least two vertically extending support members, one for each lbeam and each mounting rollers sandwiching a flange of the associated I-beam so as to be mounted for movement in a vertical direction on the associated l-beam;

c. a flexible sheet defining a form surface and extending between said support members;

d. at least two vertically arranged, eccentric rollers, one mounted on each said support member, with said sheet being trained about said rollers so that rotation of the rollers may bring the sheet into engagement with the adjacent edges of the' associated I-beam;

e. means for tensioning said flexible sheet;

. horizontally telescoping support means extending between said support members and supportingly engaging said flexible sheet;

g. means associated with each of said support members for engaging said cleats to move the respective support member upwardly on the respective lbeam;

h. means associated with said support members for maintaining the same at a desired location on the respective l-beam; and

i. further including first means joining some of said assemblies in a first closed configuration; second means joining the others of said assemblies in a second closed configuration within said first closed configuration; and means spacing said first and second configurations whereby a wall forming material receiving space is defined by said first and second configurations.

12. The apparatus as defined in claim 1 wherein the means for advancing a carriage upwardly along a beam comprises a series of spaced apart lugs attached to the outer flange of the beam, a jack attached on one end to the carriage and engaged against a lug at the other end, and a catch attached to the carriage for intermittent engagement with a lug whereby upon activation of the jack the carriage is raised until the catch engages the next higher lug.

Claims

1. Apparatus for forming A concrete wall comprising a. a plurality of generally vertical supports spaced apart along both sides of the wall being formed, each support being located opposite to another support on the other side of the wall and detachable connected to said opposing support by a plurality of spacers some of which are contained in the wall previously formed, each support consisting of separate segments detachably joined together at their ends, and the lower portion of each support being held contiguous the surface of the wall previously formed by said spacers while the upper portion extends above the portion of the wall previously formed; b. a carriage mounted for vertical movement along each support with lifting means mounted on and carried thereby for engaging contact along the length of each support section as the wall is formed for advancing the carriage upwardly along the supports as the wall is formed; c. a plurality of concrete casting assemblies located along and on both sides of the wall being formed adjacent its top, each assembly supported at its ends by two carriages on adjacent supports and each assembly having a generally vertical casting surface extending between the supports so that the assemblies together define a continuous mold extending completely around the top of the wall into which concrete is poured, whereby as the concrete hardens the carriages and assemblies are moved upwardly on the supports to form a new level of wall and, at intervals, the support segments are detached from the bottom of each support and attached to the top to provide a continuous track for the carriages; and d. wherein each support segment comprises an H-beam with the inner side flange being contiguous with a surface of the wall being formed and the outer flange being generally parallel to but spaced apart from the wall, and a plurality of rollers attached to each carriage and mounted for movement along the outer flange of the adjacent beam, at least two rollers located on opposing sides of the outer flange and on opposite sides of the beam to allow the carriage to move vertically on the support but to prevent the carriage from separating from the beam.

2. Apparatus for forming a concrete wall comprising a. a plurality of generally vertical supports spaced apart along both sides of the wall being formed, each support being located opposite to another support on the other side of the wall and detachably connected to said opposing support by a plurality of spacers some of which are contained in the wall previously formed, each support consisting of separate segments detachably joined together at their ends, and the lower portion of each support being held contiguous the surface of the wall previously formed by said spacers while the upper portion extends above the portion of the wall previously formed, b. a carriage mounted on each support with means for advancing the carriage upwardly along the supports as the wall is formed, c. a plurality of concrete casting assemblies located along and on both sides of the wall being formed adjacent its top, each assembly supported at its ends by two carriages on adjacent supports and each assembly having a generally vertical casting surface extending between the supports so that the assemblies together define a continuous mold extending completely around the top of the wall into which concrete is poured, whereby as the concrete hardens the carriages and assemblies are moved upwardly on the supports to form a new level of wall and, at intervals, support segments are detached from the bottom of each support and attached to the top to provide a continuous track for the carriages, and d. the assembly casting surface comprises the inner surface of a generally horizontal, flexible sheet whose effective length may be varied by advancing at least one end of said sheet around a roll, said roll being supported by the assembly in generally an upright position adjacent one vertical support.

2. vertically extending grip means; b. means defining a form surface extending between said structural members, said form defining means being generally horizontally extendable, c. means at each end of said form defining means and engaging the vertical guide way of the adjacent structural member for guiding said form defining means for movement in a vertical direction along said guide ways; d. a pair of jack means, one at each end of said form defining means, for selectively engaging said vertically extending grip means and for advancing said form defining means vertically upwardly on said structural members, e. means associated with at least one of said form defining means and said structural members for maintaining said form defining means at a desired vertical location on said structural members and f. said apparatus further including means for holding corresponding ones of the structural members of each pair of each assembly in spaced relation whereby the form defining means of the pair of assemblies define a concrete receiving space.

8. Apparatus for casting a concrete wall comprising a pair of assemblies arranged in spaced relation with each of said assemblies including: a. at least two vertically extending, elongated, horizontally spaced structural members each having

11. An apparatus for casting concrete walls comprising a plurality of assemblies arranged in a first and a second spaced apart closed configuration, each of the assemblies comprising: a. at least two horizontally spaced, vertically extending I-beams, each having cleats mounted thereon; b. at least two vertically extending support members, one for each I-beam and Each mounting rollers sandwiching a flange of the associated I-beam so as to be mounted for movement in a vertical direction on the associated I-beam; c. a flexible sheet defining a form surface and extending between said support members; d. at least two vertically arranged, eccentric rollers, one mounted on each said support member, with said sheet being trained about said rollers so that rotation of the rollers may bring the sheet into engagement with the adjacent edges of the associated I-beam; e. means for tensioning said flexible sheet; f. horizontally telescoping support means extending between said support members and supportingly engaging said flexible sheet; g. means associated with each of said support members for engaging said cleats to move the respective support member upwardly on the respective I-beam; h. means associated with said support members for maintaining the same at a desired location on the respective I-beam; and i. further including first means joining some of said assemblies in a first closed configuration; second means joining the others of said assemblies in a second closed configuration within said first closed configuration; and means spacing said first and second configurations whereby a wall forming material receiving space is defined by said first and second configurations.