WO2014062062A1

WO2014062062A1 - A slipform construction device and method

Info

Publication number: WO2014062062A1
Application number: PCT/NO2013/050163
Authority: WO
Inventors: Odd Jahr
Original assignee: Odd Jahr
Priority date: 2012-10-15
Filing date: 2013-09-27
Publication date: 2014-04-24
Also published as: NO20121187A1

Abstract

The present invention relating to a method and associated devices for a slipform for slipform casting of vertical or inclined wall structures of concrete. According to the invention, the slipform sides have no connecting yoke. The horizontal concrete pressure against the slipform sides, during the casting process, is transferred by vertically or obliquely upright guide beams (7) down to the underlying finished, hardened slipform-cast concrete wall (8). Without a connecting yoke, there is no physical obstacle to lifting in, with a crane for direct installation in the slip, industrially prefabricated cages (13) of vertical reinforcing bars or mats (21) of horizontal reinforcing bars.

Description

A slipform construction device and method Field of the invention

The present invention relates to a method and associated devices for a slipform for slipform casting of vertical or sloping concrete walls, as disclosed in the preamble of claims 1 and 11.

Background of the invention

In conventional slipform construction, the connecting yokes are a physical obstacle to the work of erection and tying the horizontal reinforcement and the installation of large recesses or embedment parts. The working height between the working platform and the lower edge of the yoke beams, in the case of the connecting yoke, is normally about 50- 60 cm. All reinforcement, both horizontal and upright, must be inserted by hand, bar by bar, and tied.

The main object of the present invention is to ease this task of inserting and tying the horizontal reinforcement, with the low working height under the yoke beams, which is both laborious and performed under trying working conditions.

Another object is to facilitate the practical working conditions for an industrialisation of reinforcement work by enabling the use of prefabricated reinforcement mats for the horizontal reinforcement and prefabricated reinforcement cages for the upright reinforcement.

Yet another object is to optimise the slipform construction technique in order to reduce the damaging effects that can occur at the bond of the reinforcing bars to the concrete in slipform-cast concrete structures, established in "Ausschuss 378" published by the Technical University of Munich (Technische Universitat, Miinchen). The studies concluded, inter alia, that the bond length of the horizontal reinforcement, in slipform- cast structures, had to be doubled to meet the requirements of force transfer according to normal standards. Summary of the invention

Having studied the problems, the Inventor arrived at a solution where the yokes are removed and their concrete pressure transferring function is replaced by guide beams that are upright in the sliding direction.

During the casting process, the concrete pressure is, according to the invention, transferred from the sides of the slipform to upright guide beams (vertical or inclined), which, in turn, transfer the concrete pressure down to the underlying already

slipform-cast concrete wall. The guide beams are mounted in pairs facing each other and do not move, with a centre distance of, for example, 1.5 to about 4.0 metres along the wall, whilst the slipform is lifted upwards and moves in relation to the poured concrete and the upright guide beams during the whole casting process. Normally, a slipform-cast structure is of a substantial height, such that the guide beams which transfer the concrete pressure must be extended or moved upwards as the concrete structure is cast.

In the present invention, preferably only one unspliced beam length is used for each concrete pressure transferring guide beam device, the devices according to the invention being capable of transferring the concrete pressure from the sides of the slipform even during movement of the guide beams as they are moved upwards.

Accordingly, a slipform construction device is provided, comprising at least one pair of slipform elements arranged for casting a concrete wall between them, characterised in that each of the slipform elements is attached to a respective coupling device which is movably and selectively lockably attached to a respective supporting element, each of the supporting elements in at least at one portion under its respective coupling device being supported by at least one respective supporting body, and wherein at least one connecting element is arranged to extend between the coupling devices, above the wall, and releasably connect the slipform elements via the coupling devices, whereby concrete pressure from the wall is transferred via the coupling devices to the at least one supporting body. In an embodiment, the coupling devices comprise one or more guides that are adapted for sliding or rolling contact against the supporting element and to be able to transfer forces produced by the wall being cast to the supporting element.

In an embodiment, each of the coupling devices comprises lockable engaging means for releasable cooperation with respective supports on the respective supporting element.

Each of the supporting elements comprises, in an embodiment, an elongate beam body, which via respective guiding and locking elements is selectively releasably and lockably supported on respective supporting bodies. In an embodiment, the supporting bodies are embedded in a part of the wall.

At least one of the supporting bodies for each supporting element preferably comprises adjusting means configured for adjusting the inclination of the supporting element.

In an embodiment, to each slipform element are fastened an upper working platform, a finishing scaffold there below, and an intermediate working platform.

The coupling devices preferably project up above the level of the intermediate working platform and comprise engaging means for coupling to their respective end of at least one connecting element.

In an embodiment, at least one of the supporting elements comprises a lateral supporting device that is arranged for movement along the supporting element and adapted for releasable engagement with a part of a reinforcement structure when this is lowered between the supporting elements.

A support arrangement is, in an embodiment, arranged for securing to a reinforcement structure and has a plurality of receiving means for respective reinforcing bars.

A method is also provided for casting a concrete wall using the slipform construction device, characterised in:

- that the slipform elements are lifted and slide along vertically or obliquely arranged guide beams and form the external contours of the concrete wall whilst the concrete pressure against the slipform elements is first transferred to the coupling devices and their guides, and then to the guide beams and down to the slipform-cast concrete wall below the sides of the slipform via the brackets anchored in the concrete wall, wherein, when the sides of the slipform approach the upper edge of a guide beam, a temporary tie connection is preferably established between the upright and upwardly projecting devices fastened to the sides of the slipform, during the brief period of time in which the guide beam is lifted up supportingly against the sliding or rolling load-transferring arrangements in the device or the brackets, for further slipform casting until the full height of the concrete wall is reached.

In an embodiment, the jacks for lifting the slipform sides and working platforms are preferably of a design that lifts simultaneously and at the same lifting rate, independent of uneven loads.

The whole or parts of the vertical reinforcement are preferably lifted in and installed as prefabricated cages, the guide beams being used as guides in the last part of the lowering movement as the reinforcement cages are lowered for installation.

Once the reinforcement cages have been installed, they rest against the guide beams via a supporting device that is adjustable in the longitudinal direction of the concrete wall and/or against the reinforcement cages that have already been installed or embedded.

In an embodiment, the whole or parts of the horizontal reinforcement are lifted in and installed in the form of prefabricated mesh, the guide beams being used as guides in the last part of the lowering movement as the reinforcements mats are lowered down to a level for installation on the supports. During the installation process, the reinforcement mat bars are preferably laid on a support arrangement, which has preferably been preinstalled, secured to or suspended from the reinforcement cages. The reinforcement mat bars, during installation, lie on the support arrangements and preferably lie untied on the support arrangements as they are embedded.

The sliding or rolling arrangements are in an embodiment adjustably secured in the brackets that align the guide beams in the desired sliding direction, in the same way as the sliding or rolling arrangements are adjustably secured in the coupling device. Brief description of the drawings

The invention will be explained in more detail in the following description of an embodiment of the invention, presented as a non-limiting embodiment, with reference to the attached drawings, wherein:

Figure 1 is a sectional view through an embodiment of the slipform according to the invention, and illustrates a stage in the casting of a concrete wall;

Figure 2 is a sectional view like that shown in Figure 1, and shows, inter alia, a prefabricated cage of upright reinforcing bars as it is lifted into the slipform according to the invention;

Figure 3 is a sectional view like that shown in Figure 1, and shows, inter alia, a prefabricated mesh of horizontal reinforcing bars as it is lifted into the slipform according to the invention;

Figure 4 is an enlarged section of a portion of the slipform according to the invention, and shows, inter alia, a mounting arrangement for horizontal reinforcing bars; and

Figure 5 and Figure 6 show alternative supports for engaging arrangements that are known per se for a lifting arrangement for lifting the complete slipform.

Detailed description of a preferred embodiment of the invention

Figure 1 shows a section through an embodiment of the slipform according to the invention. The two sides 1 A, IB of the slipform are fastened to their respective coupling device 10A, 10B, which in the illustrated embodiment comprise square tubular structures. One of the coupling devices 10B is shown in broken lines. Within each of the coupling devices 10A, 10B there runs a concrete pressure transferring guide beam 7 A, 7B. Each of the guide beams is supported against guides 11, preferably a sliding or rolling guide arrangement 11, in their respective coupling device 10A, 10B. Each guide 11 is fastened to its respective coupling device and can also transfer the concrete pressure. The guides 11 are (e.g., with screws) adjustably 24 secured in relation to their respective coupling device 10A, 10B so as to be able to individually adjust the direction and slip of the individual slipform sides 1 A, IB during the slipform-casting operation. Each side 1 A, IB of the slipform has three working platforms, connected to its respective coupling device 10A, 10B: an upper platform 3 (for installing the

reinforcement), an intermediate platform 2 (also for installing reinforcement and pouring the concrete), and a lower platform (in the form of a finishing scaffold) 4.

The two guide beams 7A, 7B are supported and fastened on their respective sides of the concrete wall via respective brackets 6. The brackets 6 are secured in the slipform-cast concrete wall 8 to embedded anchors 25. The force transfers between the guide beams 7 A, 7B and the brackets 6 are made by a sliding or rolling arrangement 9. The sliding or rolling arrangement 9 is adjustably 17 secured in relation to the brackets 6 so as to be able to align the guide beams 7 A, 7B in the desired sliding direction (inclination). The guide beams 7 A, 7B are supported upright (vertically or obliquely) on the brackets 6. The vertical load transfer is preferably effected by means of a spring-loaded wedge clamp (not shown) in a way that is known per se, where the pressure face of the wedge clamp against the guide beams has teeth.

Figure 1 also depicts some of a first reinforcement cage 12 that is shown partly embedded in the concrete wall, and a second reinforcement cage 13 that is in the process of being lifted in and mounted to the first reinforcement cage. The second reinforcement cage 13 is supported by an adjustable, demountable and movable supporting device 14 against one or both guide beams (only against the second guide beam 7B shown in the figures), such that it stands in the direction of the future concrete wall 8.

The coupling devices 10A, 10B preferably project up slightly above the intermediate working platform 2, partly to prevent concrete spillage on the intermediate working platform 2 from the pouring from entering the coupling devices 10A, 10B and thus preventing the action of the guide 11.

Fastened at an upper end and on the outside of the coupling device 10A, 10B are ties 16 A, 16B that extend from one of the coupling devices to the other. The ties 16 A, 16B are preferably connected in pairs to securing means on each side of each coupling device, and are adjustable in the longitudinal direction, thereby enabling the distance between the coupling devices (and thus the guide beams) to be adjusted. In another variant, just one tie can be used, which in that case is mounted in the centre of the coupling device. Before the guide beams 7 A, 7B are moved up, the ties 16 A, 16B are mounted temporarily. During the lifting of the guide beams 7A, 7B, some of the concrete pressure from the two sides 1 A, IB of the slipform will be transferred via the stays 16A, 16B. The remainder of the concrete pressure is transferred as before by the guide beams 7 A, 7B.

In connection with upward movement of the guide beams 7A, 7B, the load from the slipform on the guide beam in question is relieved, thereby allowing the engaging arrangement of the lifting jacks on the supports 26 to be released. This is done by allowing the lifting jacks on the adjacent guide beams to take over the load by lifting them up slightly. Alternatively, a support may be mounted, with a lifting arrangement attached thereto, between the upper bracket 6 and the lower edge of the coupling device 10.

Figure 2 shows the above-mentioned second prefabricated reinforcement cage 13 of upright reinforcing bars during a lifting-in operation. The lifting-in operation is carried out using a crane arrangement 19 (only a wire is shown) where the reinforcement cage 13 is suspended from a lifting yoke 20.

When the second reinforcement cage 13 is brought in over the upper working platform 3, the reinforcement cage 13 is fastened to a sliding means 18 that is movably supported on the guide beam 7B, such that it slides along this beam and guides the reinforcement cage 13 down into a secure position where it can be anchored to the reinforcing bars in the already embedded and projecting first reinforcement cage 12.

Figure 3 shows a prefabricated mat 21 of horizontal (i.e., substantially horizontal) reinforcing bars during a lifting-in operation. The lifting-in operation is carried out using a crane arrangement 19 (only a wire is shown) where the mat 21 is suspended from a lifting yoke 22.

When the mat 21 is brought in over the upper working platform 3, the mat 21 is pressed against the guide beam 7B, for example, with the aid of a rope (not shown) that is pulled against the upper working platform 3. The mat 21 can then be lowered down and slide along the guide beam 7B to a level for mounting on a support arrangement 23. This is illustrated in more detail in Figure 4, which shows the reinforcement mat 21 lowered to its installation level. The arrows show the movements the mat 21 makes, with the aid of the crane arrangement 19, for insertion/installation of the reinforcing bars 15 of the mat on the support arrangement 23.

Figures 5 and 6 show alternative supports 26; 26' for engaging arrangements that are known per se for a lifting arrangement (not shown) for lifting the complete slipform, in the guide beam 7 A. The lifting arrangement may be hydraulic, pneumatic or

electromechanical. The supports 26 can preferably be milled into the guide beam during the milling of the beam itself.

In the solution according to the invention, the concrete pressure acting on the respective sides 1 A, IB of the slipform is transferred to the freshly cast concrete wall 8 under the slipform via the guide beams 7A, 7B and the guides 11 (which, for example, comprise sliding or rolling arrangements) that are arranged fastened inside the coupling devices 10A, 10B. The coupling devices 10A, 10B are firmly secured to the respective sides 1 A, IB of the slipform. The guide beams 7 A, 7B remain stationary whilst the slipforms 1 A, IB are lifted and slide upwards on the guide beams 7A, 7B.

When one or both of the slipform sides 1 A, IB have been lifted up into the upper portion of their respective guide beams 7A, 7B, it is possible, as an alternative, to mount the respective ties 16 A, 16B just above the coupling devices 10A, 10B. The ties 16 A, 16B can then transfer their part of the concrete pressure between the respective sides 1 A, IB of the slipform, whilst the respective guide beam 7A, 7B is lifted up to a new desired level. During the lifting movement, the guide beam 7A, 7B is still guided by the guides 11 and/or the sliding or rolling arrangements 9.

In the solution according to the invention, the horizontal reinforcement can be installed in the form of prefabricated mats 21. The mats 21 may be of a group of welded bars or loose bars laid in a lifting jig that is lifted into the slipform. Ropes (not shown) may be mounted on the mats 21 to facilitate the receipt of the upper working platform 3. By means of the ropes, the mat 21 is directed to rest against one of the guide beams 7 A, 7B, after which the mat 21 is lowered down and uses the guide beam as a guide during the lowering to the installation level of the bars. At the installation level, the crane arrangement 19 moves the reinforcement mats 21 over from the guide beam 7 A, 7B towards the installed upright reinforcement in either the first reinforcement cage 12 or the second reinforcement cage 13. The reinforcement mats 21 can then be lowered and come to rest against the support arrangement 23 and are thus fully installed for embedment without having to be tied to the upright reinforcement. The support arrangement 23 is fastened to or welded in the reinforcement cages 12, 13 preferably in connection with the prefabrication of the cages.

In the solution according to the invention, the upright reinforcement is installed in the form of prefabricated welded cages (referred to as first and second reinforcement cages 12, 13 above). The second reinforcement cage 13 has had ropes mounted (not shown) to facilitate its receipt on the upper working platform 3. By means of the ropes, the cage 13 is directed towards the desired guide beam 7A, 7B where one or more fastening arrangements 18 are arranged between the cage 13 and the guide beam 7 A, 7B. The anchorage of the fastening arrangement 18 in the guide beam in question is sliding and will guide the reinforcement cage 13 into the right position in relation to the upward projecting bars in the embedded first reinforcement cage 12, as the second

reinforcement cage 13 is lowered into place.

The use of the guide beams 7A, 7B as guides for the last part of the downward movement during installation of both the second reinforcement cage 13 and the reinforcement mats 21, has significantly reduced the impact that strong wind may have during slipform casting when lifting in the reinforcement.

By means of the present invention, a method has been arrived at with devices and arrangements which make it possible to construct vertical or inclined concrete structures using a slipform, without the yokes for the reinforcement which are an operational obstacle.

According to the invention, a large quantity of both horizontal and upright

reinforcement which has been industrially welded together in mats or cages can be lifted in and installed in one lifting operation. An industrial form of production with welding jigs and robots, inside a workshop providing a protected working environment, will result in optimal working conditions compared with the working conditions out in the open and cramped working conditions out on a slipform. The optimal working conditions mean substantially enhanced work efficiency and hence reduced labour costs. In addition, the use of welding jigs allows the centre distance of the reinforcing bars to be welded so accurately that the theoretically calculated centre distances for the concrete structure can be used, even if they are fractions of a centimetre. This means a reduction in the use of reinforcement and associated work hours compared with conventional slipform casting where, based on experience, whole centimetres are always used.

According to the invention, the centre distance checking of the reinforcing bars is reduced to the checking of the mounted centre distance for the bars in the welding jigs and is done only once. In today's slipform construction, this checking takes place during the whole slipform construction operation and at all times of the day.

In conventional slipform casting, where the reinforcing bars are installed by hand, one bar at a time, the slipform crew is dependent on short bar lengths in order, from a load perspective, to be able to handle them manually. By being able, according to the invention, to lift in and install the reinforcing bars in the form of mats and cages, using a crane arrangement, the slipform crew is virtually independent of the weight of the mats or cages. Therefore, with the present invention it is possible to use substantially longer reinforcing bars, both for mats and for cages, compared with conventional slipform construction. This means a considerable reduction in the number of splice lengths with a corresponding reduction in the total amount of reinforcement and work hours.

With the present invention, the amount of manual labour out on the slipform is reduced significantly in that it is possible to lay the bars for a whole mat 21 in one work operation on a support arrangement 23. The support arrangement 23 has a correct prechecked centre distance for the bars 15 and is constructed with upward projecting hooks so that the reinforcing bars 15 do not need to be tied.

In the method according to the invention, the slipform sides will be pressed against the vertical or obliquely upright guide beams by the concrete pressure. The slipform sides 1A, IB will be lifted up by electromechanical, hydraulic or pneumatic lifting jacks (not shown) in the direction in which the upright guide beams 7A, 7B are arranged, preferably by lifting jacks which all lift simultaneously, at the same rate and independent of varying and/or uneven loads. The slipform sides 1 A, IB will thus not have any tilting/balancing movements that occur with the lifting jacks that are used today and which may result in reduced bonding for the reinforcing bars, which has been established in Ausschuss 378.

Claims

Patent claims

1. A slipform construction device, comprising at least one pair of slipform elements (1 A, IB) arranged for casting a concrete wall (8) between them, characterised in that each of the slipform elements (1 A, IB) is attached to a respective coupling device (10A, 10B) which movably and selectively lockably is attached to a respective supporting element (7 A, 7B), each of the supporting elements in at least one portion under its respective coupling means being supported by at least one respective supporting body (6), and at least one connecting element (16A, 16B) is arranged to extend between the coupling devices (10A, 10B), above the wall (8), and releasably connect the slipform elements via the coupling devices (10A, 10B), whereby concrete pressure from the wall is transferred via the coupling devices (10A, 10B) to the at least one supporting body (6).

2. A device according to claim 1, wherein each of the coupling devices (10A, 10B) comprises one or more guides (11) that are adapted for sliding or rolling contact against the supporting element (7 A, 7B) and to be able to transfer forces produced by the wall (8) being cast to the supporting element.

3. A device according to claim 1 or claim 2, wherein each of the coupling devices (10A, 10B) comprises lockable engaging means for releasable cooperation with respective supports (26) on the respective supporting element (7 A, 7B).

4. A device according to any one of the preceding claims, wherein each of the supporting elements (7 A, 7B) comprises an elongate beam body which via respective guiding and locking elements (9) is selectively releasably and lockably supported on respective support bodies (6).

5. A device according to any one of the preceding claims, wherein the support bodies (6) are embedded in a part of the wall (8).

6. A device according to any one of the preceding claims, wherein at least one of the support bodies (6) for each supporting element comprises adjusting means (17) configured for adjustment of the inclination of the supporting element.

7. A device according to any one of the preceding claims, wherein to each slipform element (1 A, IB) are fastened an upper working platform (3), a finishing scaffold (4) there below, and an intermediate working platform (2).

8. A device according to claim 7, wherein the coupling devices (10A, 10B) project up above the level of the intermediate working platform (2) and comprise engaging means for connecting to their respective end of at least one connecting element (16A, 16B).

9. A device according to any one of the preceding claims, wherein at least one of the supporting elements comprises a lateral supporting device (18) that is arranged for movement along the supporting element and adapted for releasable engagement with a portion of a reinforcement structure (13) when this structure is lowered down between the supporting elements (7 A, 7B).

10. A device according to any one of the preceding claims, further comprising a support arrangement (23) adapted for securing to a reinforcement structure (12, 13) and having a plurality of receiving bodies for respective reinforcing bars (15).

11. A method for casting a concrete wall (8) with the aid of the slipform

construction device as disclosed in any one of claims 1-10, characterised in:

- that the slipform elements (1 A, IB) are lifted and slide along vertically or obliquely arranged guide beams (7 A, 7B) and form the external contours of the concrete wall (8) whilst the concrete pressure against the slipform elements (1 A, IB) is first transferred to the coupling devices (10A, 10B) with their guides (11), and then to the guide beam (7 A, 7B) and down to the slipform-cast concrete wall (8) below the sides (1 A, IB) of the slipform via the brackets (6) anchored in the concrete wall (8), wherein, when the sides (1 A) and (IB) of the slipform approach the upper edge of a guide beam (7 A) or (7B), a temporary tie connection (16) is preferably established between the upright and projecting devices (10A) and (10B) fastened to the sides (1 A) or (IB) of the slipform, during the brief period of time in which the guide beam (7 A) or (7B) is lifted up supportingly against the sliding or rolling load-transferring arrangements (11) and (9) in the device (10A) or (10B) or the brackets (6), for further slipform casting until the full height of the concrete wall (8) is reached.

12. A method according to claim 11, wherein the jacks for lifting the slipform sides (1 A) and (IB), working platforms (2), (3) and (4), are preferably of a design that lifts simultaneously and at the same lifting rate, independent of uneven loads.

13. A method according to claim 11 or claim 12, wherein all or parts of the vertical reinforcement are lifted in and installed in the form of prefabricated cages (13), the guide beams (7) being used as guides (18) in the last part of the lowering movement, when the reinforcement cages (13) are lowered for installation.

14. A method according to claim 3, wherein the reinforcement cages (13), once installed, rest against the guide beams (7) via a supporting device (14), adjustable in the longitudinal direction of the concrete wall (8), and/or against the reinforcement cage (13) already installed or embedded.

15. A method according to any one of claims 11-14, wherein the whole or parts of the horizontal reinforcement (15) are lifted in and installed in the form of prefabricated mats (21), wherein the guide beams (7) are used as guides in the last part of the lowering movement as the reinforcement mats (21) are lowered down to a level for installation on the supports (23).

16. A method according to claim 15, wherein the bars (15) of the reinforcement mats, during the installation process, are laid on a support arrangement (23), a support arrangement (23) preferably being preinstalled fastened to or suspended from the reinforcement cages (13).

17. A method according to claim 16, wherein the bars (15) of the reinforcement mats, during mounting on the support arrangements (23), preferably lie untied on the support arrangements (23) as they are embedded.

18. A method according to any one of preceding claims 11-17, wherein the sliding or rolling arrangements (9) are adjustably (17) secured in the brackets (6) that align the guide beams (7) in the desired sliding direction, in the same way as the sliding or rolling arrangements (11) are adjustably (24) secured in the coupling device (10).