An apparatus for forming a concrete tubular member, in particular a tunnel segment or a pipe segment

Abstract

An apparatus (1) for forming a concrete tubular element, comprising: - a rotating drum (2) driven by a motor (3), which extends along a longitudinal axis (L) between an inlet end (4) and an outlet end (5) and comprises a guide (6) helically wound on at least a portion of the drum (2) starting from the inlet end (4); - a fixed retaining wall (7) extending circumferentially around the rotating drum (2) at the inlet end (4) thereof; - a reinforcement feeder (9) configured to feed a continuous reinforcement band (10) on the guide (6) to the rotating drum (2) at the inlet end (4), so that, as the drum (2) rotates, the reinforcement band (10) is progressively wound around the drum (2) along the guide (6); - a concrete feeder (14) configured to feed concrete on the fed reinforcement band (10), so that, as the drum (2) rotates, the reinforcement band (10) progressively wound along the guide (6) is progressively covered by a continuous layer of concrete.

Description

Technical Field

[0001] The present invention relates to an apparatus for forming concrete tubular elements, such as concrete segments of tunnels (especially underwater tunnels) or concrete segments of general pipelines. Background Technology

[0002] These are associated with the tunneling field (especially underwater or subsea tunnels) and consist of interconnected concrete segments manufactured in a factory and then transported to the tunnel site. These tunnel segments are very large (typically up to 20 meters in diameter), and due to their enormous size, their transportation is extremely difficult, expensive, time-consuming, and environmentally impactful. Summary of the Invention

[0003] Therefore, the object of the present invention is to provide an apparatus for forming concrete tubular components, such as tunnel segments or pipeline segments, which may be formed directly on the construction site, thereby substantially avoiding the transportation of the segment and reducing the cost and total time of tunnel / pipeline construction as well as the environmental impact.

[0004] This and other objectives are achieved by the apparatus for forming concrete tubular elements according to claim 1.

[0005] The dependent claims define possible advantageous embodiments of the invention. Attached Figure Description

[0006] To better understand the present invention and appreciate its advantages, some non-limiting exemplary embodiments will be described below with reference to the accompanying drawings, wherein: - Figure 1 This is a schematic diagram of an apparatus for forming a concrete tubular element according to an embodiment of the present invention; - Figure 2 yes Figure 1 A schematic side view of the rotating drum of the equipment; - Figure 3 This is a schematic diagram of a reinforcing bar strip for the device according to an embodiment of the present invention. Detailed Implementation

[0007] Reference Appendix Figure 1 To be continued Figure 2 The attached figure, referenced by reference numeral 1, shows a schematic diagram of an apparatus for forming concrete tubular elements. According to the preamble of this specification, the tubular elements may include, for example, segments of tunnels (particularly underwater tunnels) or pipe sections.

[0008] Device 1 includes a rotating drum 2 driven by a motor 3 (e.g., an electric actuator). A transmission is operatively inserted between the drum 2 and the motor 3. The drum 2 extends along a longitudinal axis L between an inlet end 4 and an outlet end 5. For example, the drum 2 may be made of steel. Its diameter depends on the desired diameter of the tubular element to be formed.

[0009] The roller 2 can be positioned such that the longitudinal axis L is horizontal, or alternatively tilted to form an angle α with the horizontal support base 100, preferably with the inlet end 4 higher than the outlet end 5.

[0010] According to an embodiment, the device 1 includes a means 19 for adjusting the inclination of the longitudinal axis L of the roller 2 (i.e., for modifying the angle α). For example, such a means may include a hydraulic, pneumatic, or electric actuator.

[0011] The roller 2 includes a guide 6 spirally wound on its outer surface, extending along the longitudinal axis L from the inlet end 4, preferably extending only a portion of the roller, i.e., not the entire length of the roller. For example, the guide 6 may include a spiral groove formed on the outer surface of the roller 2. The function of the guide 6 will be described in more detail below. Preferably, the guide 6 extends at least three turns along the longitudinal axis L.

[0012] The device 1 also includes a retaining wall 7 that extends circumferentially around the roller 2 at the inlet end 4 of the roller 2, maintaining a radial distance from the roller. Preferably, the retaining wall 7 extends circumferentially around the roller by less than 360°, thereby forming an opening 8 near the inlet end 4 that is accessible to the roller 2. Preferably, the opening 8 is located at the highest radial position of the roller 2. In an embodiment, the retaining wall 7 extends circumferentially by at least 180° from the highest radial position of the roller, preferably up to 270°.

[0013] In the implementation, the width of the fixed retaining wall 7 is the same as or substantially the same as the extension range of the guide 6 along the longitudinal axis L, that is, it only covers the longitudinal portion of the guide 6 on the outer surface of the roller 2 from the inlet end 4.

[0014] The device 1 also includes an armour feeder 9, which is configured to feed a continuous strip of armour 10 on a guide 6 to the drum 2 at the drum inlet end 4, for example at the opening 8.

[0015] Advantageously, the pitch of the helically wound guide 6 is the same as or substantially the same as the width of the reinforcing bar strip 10. More advantageously, the guide 6 (and / or the reinforcing bar strip 10) is configured such that, as the reinforcing bar strip 10 is supplied on the rotating roller 2, it gradually locks onto the guide itself, rising radially relative to the outer surface of the roller (e.g., from the bottom of the helical groove), preferably located at a radially intermediate position between the outer surface of the roller 2 and the retaining wall 7, and following the helical path of the guide 6 itself.

[0016] According to one embodiment, the rebar feeder 9 includes a track 11 for moving the rebar strip 10 toward the roller 2 and a rebar strip source 12 from which the rebar strip 10 is taken and placed on the track 11. The rebar strip source 12 may be a container for holding pre-fabricated rebar strips, or alternatively may include a device for manufacturing the rebar strip 10 on-site, such as a forging and welding machine. The track 11 is preferably positioned on the tower 17 such that it has access to the opening 8.

[0017] 10 (reinforcing bar strip) Figure 3 The reinforcing strip 10 may include, for example, a reinforcing mesh made of steel. Advantageously, the reinforcing strip 10 includes anchoring devices 13 on its longitudinal sides, which are configured such that when two portions of the reinforcing strip 10 are placed side by side, they are interconnected by the anchoring devices 13. For example, the anchoring devices 13 are zipper-shaped. In this way, when continuous portions of the reinforcing strip supplied to the roller are placed side by side on the guide 6 as the roller rotates, they are interlocked by the anchoring devices 13. The anchoring devices 13 may also form a locking device for locking the reinforcing strip 10 to the guide 6.

[0018] Back Figure 1 and Figure 2 The device 1 also includes a concrete feeder 14, which is configured to supply concrete to the guide member 6 at the drum inlet end 4, such that as the drum 2 rotates, the steel strip 10 supplied to the guide member 6 is gradually covered by concrete, and the steel strip 10 interlocked side by side by the anchoring device 13 is partially covered by a continuous layer of concrete.

[0019] More specifically, in this embodiment, the concrete feeder 14 includes a container 15 (e.g., with a mixer), and a first concrete feeder 16 and a second concrete feeder 17. The first concrete feeder 16 supplies concrete onto the track 11, such that the reinforcing bar strip 10 is first covered with concrete before reaching the drum 2. The second concrete feeder 17 supplies concrete onto the guide 6 near the drum inlet end 4, for example at the opening 8, such that the already covered reinforcing bar strip is further covered with concrete and clamped therein. In this way, the side-by-side portions of the reinforcing bar strip 10 are progressively and continuously clamped in a single continuous layer of concrete. During the rotation of the drum 2, the concrete layer clamping the reinforcing bar strip 10 is pressed and shaped by the retaining wall 7, for which the retaining wall 7 may optionally include suitable rollers (not shown) on the side facing the drum 2.

[0020] Due to the rotation of the roller 2 and the presence of the spiral winding guide 6, a concrete tubular element reinforced with a spirally wound steel strip 10 (also continuous) is formed and moves along the longitudinal axis L toward the roller outlet end 5. After the tubular element reaches the desired length, the supply of both the steel strip 10 and the concrete is stopped, and the formed tubular element can be pushed out of the rotating roller.

[0021] Advantageously, the concrete is formulated such that it does not fully harden during the formation of the tubular element, but rather hardens at the end of the process. In one embodiment, the concrete is not fully hardened when the formed concrete tubular element is ejected from the rotating drum 2.

[0022] It should also be noted that when the partially formed tubular element extends beyond the end of the spirally wound guide 6, it can be further processed or covered, for example with a protective layer, such as made of aluminum or other protective materials.

[0023] The tubular elements thus formed can be manufactured directly on-site and connected longitudinally to form, for example, tunnels or pipes, without the need for long-distance transport from the factory.

[0024] With respect to the described embodiments of the apparatus for forming concrete tubular elements, those skilled in the art may make various additions, modifications, or substitutions with functionally equivalent elements to meet specific temporary needs without departing from the scope of the appended claims.

Claims

1. An apparatus (1) for forming a concrete tubular element, comprising: - A rotating drum (2) driven by a motor (3) extends along a longitudinal axis (L) between an inlet end (4) and an outlet end (5), and includes a guide (6) that is spirally wound around at least a portion of the drum (2) starting from the inlet end (4). - A fixed retaining wall (7) extends circumferentially around the rotating drum at the inlet end (4) of the rotating drum (2); - A rebar feeder (9) is configured to supply a continuous strip of rebar (10) on a guide (6) to the rotating drum (2) at the inlet end (4) such that as the drum (2) rotates, the strip of rebar (10) gradually wraps around the drum (2) along the guide (6); - A concrete feeder (14) is configured to supply concrete onto the supplied reinforcing bar strip (10) such that as the roller (2) rotates, the reinforcing bar strip (10) that is gradually wound along the guide (6) is gradually covered by a continuous layer of concrete.

2. The device (1) according to claim 1, wherein, The guide (6) extends at least three turns along the longitudinal axis (L) of the roller (6).

3. The device (1) according to claims 1 and 2, wherein, The guide (6) is configured such that, for each turn around the roller (2), portions of the reinforcing bar strip (10) wound along the guide (6) are arranged side by side with portions of the reinforcing bar strip (10) of the previous turn.

4. The device (1) according to any one of the preceding claims, wherein, The pitch of the spirally wound guide (6) is the same as or substantially the same as the width of the reinforcing bar strip (10).

5. The device (1) according to any one of the preceding claims, wherein, The guide (6) and / or the reinforcing strip (10) are configured such that the reinforcing strip (10) on the guide (6) is positioned radially at the midpoint between the outer surface of the roller (2) and the fixed retaining wall (7) with the roller (2) being radially raised relative to the outer surface of the roller (2).

6. The device (1) according to any one of the preceding claims includes a locking device for locking the reinforcing bar strip (10) onto the guide (6).

7. The device (1) according to any one of the preceding claims, wherein, The reinforcing strip (10) includes a mesh having anchoring devices (13) on its longitudinal sides, the anchoring devices being configured such that when two parts of the reinforcing strip are placed side by side, the two parts are connected to each other by the anchoring devices (13).

8. The device (1) according to claims 6 and 7, wherein, The anchoring device (13) forms the locking device for locking the reinforcing bar strip (10) to the guide member (6).

9. The device (1) according to claim 7 or 8, wherein, The anchoring device (13) is zipper-shaped.

10. The device (1) according to any one of the preceding claims, wherein, The fixed retaining wall (7) extends circumferentially around the rotating drum (2) by less than 360°, thereby forming an opening (8) near the inlet end (4) that can access the rotating drum (2).

11. The device (1) according to any one of the preceding claims, wherein, The width of the fixed retaining wall (7) is the same as or substantially the same as the extension range of the guide (6) along the longitudinal axis (L) of the roller (2).

12. The device (1) according to any one of the preceding claims, wherein, The rebar feeder includes a rebar strip source (12) and a track (11) for moving the rebar strip (10) from the rebar strip source (12) to the inlet end (4) of the roller.

13. The device (1) according to the preceding claim, wherein, The steel strip source (12) includes a container for storing the prefabricated steel strip (10) or a machine for producing the steel strip (10).

14. The device (1) according to claim 12 or 13, wherein, The concrete feeder (14) includes a first concrete feeder (16) for supplying concrete onto the track (11) such that the reinforcing bar strip (11) is partially covered with concrete on the track before reaching the inlet end (4) of the roller (2).

15. The device (1) according to any one of the preceding claims, wherein, The concrete feeder (14) includes a second concrete feeder (17) for supplying concrete onto the guide (6) near the inlet end (4) of the roller, such that the reinforcing bar strip (10) is gradually and continuously covered with concrete along the guide (6).

16. The device (1) according to any one of the preceding claims, wherein, The longitudinal axis (L) of the rotating drum (2) is inclined, such that the inlet end (4) is higher than the outlet end (5).

17. The device (1) according to any one of the preceding claims includes an adjustment device for adjusting the inclination of the longitudinal axis (L) of the rotating drum (2).

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