Floating foundation, floating body made of floating foundations, and method for producing a floating foundation

Abstract

The invention relates to a floating foundation (1) comprising an expanded mineral material, namely an expanded altered volcanic glass, and additives, namely water, cement, and at least one fiber additive and / or silane, wherein water is contained in a mass fraction of 20%, cement is contained in a mass fraction of 5 to 20%, the mass fraction of the at least one fiber additive equals maximally (23), and the mass fraction of the silane equals maximally (1). The invention additionally relates to a floating body made of floating foundations (1) and to a method for producing a floating foundation (1).

Description

[0001] Floating foundation, floating body made of floating foundations and method for producing a floating foundation

[0002] Description

[0003] The present invention relates to a floating foundation used to permanently place, secure, and anchor technical equipment on non-load-bearing soils or water surfaces. Several of these floating foundations can be combined to form larger objects, substantive floating bodies. Furthermore, the present invention also relates to a method for producing floating foundations.

[0004] Description of the invention

[0005] The state of the art today is primarily floating foundations made of reinforced concrete with a core of Styrofoam and / or Styrodur. These can be concreted together from individual modules to form large floating platforms for cranes, machinery, floating bridges, jetties, and port facilities.

[0006] The disadvantages of these constructions are corrosion, the high dead weight and the robust infrastructure required for their use, such as solid roads and loading edges, oversized crane technology, etc. In addition, Styrofoam is harmful to microorganisms in the water, and the overall construction can only be recycled to a very limited extent.

[0007] Depending on the intended use, the draught due to deadweight and maximum load capacity are in a ratio of 50:50 to 70:30. There are application examples where the high deadweight is an advantage (e.g. as a breakwater), but when used as a buoyancy body (e.g. as a floating foundation), the high deadweight is detrimental, since with identical buoyancy each additional deadweight counteracts the maximum load capacity and reduces the corresponding payload.

[0008] A modular platform made of concrete is, for example, characterized by the writing

[0009] WO 90 / 08 059 A1 discloses this. Here, too, the dead weight is the major disadvantage. Floats made of conventional steel construction or shipbuilding made of steel or aluminum and other suitable materials, designed as hollow bodies, have been around for decades. The disadvantage of these solutions is a high center of gravity, and the design requires technical testing / certification for long-term use. A representative document on this technology is DE 20 2012 004 349 U1. If damaged, these metal floats fill with water, making them not the optimal solution for long-term use.

[0010] Furthermore, lightweight concrete material for special applications is known from the prior art, which comprises expanded altered volcanic glass and additives such as water, cement, fibrous industrial waste and / or silanes.

[0011] For example, DE 20 2017 001 061 U1 discloses a lightweight concrete material consisting of at least one lightweight mineral aggregate surrounded by a foamed or porous, preferably cement- or water glass-based binder matrix, aggregates, and optionally additives and / or fillers. The lightweight concrete material is buoyant and water-resistant and serves in particular as a slab-shaped base or foundation element for floating facilities such as offshore wind and solar farms.

[0012] US 2017 / 0 306 213 A1 discloses compositions of delayed-setting cement slurries. Furthermore, methods for using the delayed-setting cement slurries resulting from the combination of the delayed-setting cement slurries are also described.

[0013] The invention is based on the object of providing a floating foundation that is lightweight, has a high load-bearing capacity, and, compared to prior art objects, exhibits a high resistance to natural influences. Furthermore, the object of the invention is to provide a floating body comprising floating foundations according to the invention. Finally, the object of the invention is to provide a method by which the floating foundations according to the invention can be manufactured.

[0014] The solution to the problem with regard to the floating foundation is achieved with the features of claim 1, wherein the subclaims 2 to 11 describe further embodiments. The solution to the problem with regard to the floating body is achieved with the features of independent claim 12. The solution to the problem with regard to the method is achieved with the features of independent claim 13. Claims 14 to 15 show further embodiments of the method.

[0015] The floating foundation according to the invention comprises an expanded mineral material, namely an expanded altered volcanic glass, preferably perlite, and additives, namely water and cement, as well as at least one fibrous additive and / or silane. Perlite contains 2 to 5 mass percent crystal water and has a density of approximately 900 to 1,000 kg / m³ 3(Bulk density of raw pearlite). By annealing at approximately 800 °C to 1,000 °C, pearlite expands to fifteen to twenty times its original volume and then has a bulk density of 50 to 100 kg / m 3and a thermal conductivity of A = 0.040 to 0.070 W / (m K). The expansion process makes it very light without losing its load-bearing properties. The additives essentially serve as a binding agent for the perlite, with water and cement each being present in amounts of 5 to 20 percent by mass. Industrial waste in the form of recycled fibers can be used as a fibrous additive to increase the load-bearing capacity of the floating foundation. In addition to recycled glass fiber and carbon fiber, recycled fibers also include fluff, which is the airborne fraction of secondary fuels that play a role in waste incineration and the concrete industry, for example. Fluff is a waste product that usually has to be disposed of at great expense. However, in its fibrous form, the invention increases the load-bearing capacity of the floating foundation by increasing its strength and structural stability.Natural fibers, such as wood, hemp, sisal, or flax fibers, are also suitable as fibrous additives. The target density of the floating foundation material is between 300 kg / m. 3 and 400 kg / m 3 , where 300 kg / m 3 are to be considered as optimum.

[0016] The water-repellent nature of the floating foundation is enhanced, in particular, by the addition of silanes. At least one fibrous additive can be included in the floating foundations at a concentration of 5 to 12 percent by mass, while the silanes can be present at a maximum of 1 percent by mass.

[0017] According to one embodiment, the floating foundation further comprises a plastic or a plastic mixture. The plastic(s) are preferably of biological origin, for example, biopolymers from bacteria, algae, or fungi. The plastic or plastic mixture serves to modify the technical-physical properties of the floating foundation in a specific application. For example, it serves to increase (compressive) strength and flexibility, improve resistance to water absorption by increasing diffusion stability, and / or improve acid resistance. Furthermore, the additives serve to increase the frost and de-icing salt resistance of the overall mixture.

[0018] According to a special embodiment of the floating foundation according to the invention, an outer coating is applied to the floating foundation. Thus, the surfaces that are located in the water during use or in wet areas in marshy or muddy areas can be additionally coated with a water-repellent coating or a corresponding surface. To increase slip resistance, the surface located on top in the use position can be covered with anti-slip materials or coatings. Depending on requirements, the surface can also have other unspecified properties.

[0019] According to a further embodiment of the floating foundation according to the invention, the floating foundation has coupling elements on all sides, wherein the coupling elements are designed such that they can be coupled to corresponding coupling elements on other floating foundations. This allows several floating foundations to be easily joined together with short chains to form a larger, movable structure. To form a larger, fixed structure, the elements can also be screwed together or have plug-in or locking elements, depending on the requirements of the floating foundation. Studs arranged in corresponding concave recesses on adjacent floating foundations also represent a possible connection. Other connection possibilities are not excluded.

[0020] According to one embodiment, the coupling elements comprise a steel tube for connecting two floating foundations. The steel tube has a trapezoidal thread on both sides and a steel profile in the center, which serves as an engagement point for a hook wrench. At the same time, the profile generates a slight contact force when tightened to secure the floating foundations to one another. At each end of a group of floating foundations, the steel tube is provided with an end tube with a trapezoidal thread. This end tube, in turn, has a steel profile as an engagement element for the hook wrench and a screw lock to prevent loosening (twisting of the steel tubes / end tubes). The floating foundations can be secured to one another against twisting with a sheet similar to a T-profile. In particular, several steel tubes can be provided per coupling element.

[0021] According to a further embodiment, the floating foundation further comprises at least one pipe-fixed threaded anchor. The at least one pipe-fixed threaded anchor comprises a pipe running horizontally in the floating foundation. The horizontal pipe is connected to a vertical steel rod. The vertical steel rod has a threaded pipe section which terminates at a surface of the floating foundation. The horizontal pipe can be provided with a special sleeve to which the vertical steel rod is welded. Due to the threaded pipe section on the surface, the forces to be absorbed are distributed via the vertical steel rod to the horizontal pipe, which can be connected to the coupling elements. In this way, the forces to be absorbed are optimally distributed in the floating foundation and across neighboring floating foundations.

[0022] According to a further embodiment of the floating foundation according to the invention, the floating foundation is preferably designed such that its own weight is balanced by its load-bearing capacity and its reserve load-bearing capacity. This means that the floating foundation sinks by one-third due to its own weight, then has a load-bearing capacity of 33%, which corresponds to a further third of sinking, and finally has a reserve load-bearing capacity of another 33% until full submersion is reached. This division is based on the floating body volume of the floating foundation.Such a division is of considerable importance for the planning, since machines or structures arranged on the floating foundation can be clearly designed in advance and later unforeseeable changes in the load do not endanger the safety of the floating foundation or a structure made up of several floating foundations.

[0023] According to a further embodiment of the floating foundation according to the invention, the floating foundation is non-combustible. Given the manufacturing method of the floating foundation, ignition should be fundamentally impossible. However, to prevent certain hazards from hazardous substances stored on the floating foundation, the surface can be additionally coated with a fire-retardant layer, for example.

[0024] According to a further embodiment of the floating foundation according to the invention, the floating foundation has a very high compressive strength. This can be achieved by increasing the mass fraction of the at least one fibrous additive. The use of longer fibers or mats is also conceivable. In any case, this makes it possible to even support buildings, cranes, or other machinery on the floating foundation or a structure consisting of several floating foundations.

[0025] According to a further embodiment of the floating foundation according to the invention, the floating foundation absorbs no, or at least almost no, water. While this can be achieved by a coating as described above, it is further improved by adding a higher proportion of silane and / or plastic during production. This significantly increases the service life.

[0026] In order not to limit usability to a small structure such as a single floating foundation, floating bodies can be provided from floating foundations in which at least two floating foundations according to the invention are coupled to form larger units by means of coupling elements. These coupling elements can be frames that are placed outside a plurality of floating foundations. However, these are then only suitable for moorings and not for navigation or construction. If machines or buildings are to be erected on such a floating body, the screw connection would be necessary in at least one layer, but preferably in at least two or, better still, more layers for high loads. For this purpose, cavities through which a rod or a cable structure is guided can already be provided in the floating body during production or can be inserted after production.This allows several foundations to be joined together, both longitudinally and transversely, to form a large floating body. Connecting the elements to each other using snaps or tenons further increases the possible load.

[0027] According to the process for producing a floating foundation, an altered, volcanic glass is first expanded at a temperature range of 800 to 1000 degrees Celsius. The portion of the resulting perlite, for example, with particularly small grain sizes is then filtered out. A maximum grain size can be specified here, with finer materials helping to improve the overall product during further processing. The filtered material is then mixed with the additives water and cement, as well as at least one fibrous additive and / or silane and / or a plastic / plastic mixture, depending on the requirements of the floating foundation. The finished mixture is poured into a mold to harden, taking into account size reduction during hardening.To ensure that all floating foundations manufactured in molds are consistent in size, each cured floating foundation undergoes a surface treatment. This allows a wide variety of precisely dimensioned foundations to be easily produced using a milling machine.

[0028] The at least one fibrous additive and / or the silanes and / or the plastic / plastic mixture are preferably introduced in solid or liquid form during the mixing process. After a basic mixture of the altered volcanic glass with water and cement, the mixing process undergoes a further cycle until all additives are completely mixed with the basic mixture. A minimum wetting of the lightweight mineral material is required to fully ensure the desired material properties of the resulting lightweight concrete mixture.

[0029] The lightweight concrete mix is ​​preferably produced in a specially designed mixing apparatus, which ensures a new type of gentle mixing of the raw materials. The innovative feature of this apparatus is the use of rotationally symmetrical components in a mixing drum, instead of flat stirring elements. The introduced material is swirled during the mixing process, particularly in the area of ​​the rotating elements, and the resulting suction and pressure effects ensure low-friction mixing. This innovative mixing technology is gentler on the material than conventional concrete mixers and ensures a larger grain size of the mineral substances in the mixture at the time of pouring.

[0030] In a particular embodiment of the method according to the invention for producing a floating foundation, hollow bodies are inserted into the mold before the mixture is poured into the mold, creating cavities in the floating foundation. When the mixture is poured into the mold, the mixture encloses these hollow bodies. As it hardens, cavities are created through which fastening elements can be inserted.

[0031] Another method for producing a floating foundation is to drill holes through the floating foundation after or before surface treatment. Drilling after curing prevents deformation in the cavity during curing and thus promotes a precise fit between two adjacent floating foundations.

[0032] The preferred floating foundations are 2.25 m wide and 2.25 m long, with a height of 1.25 m, 2.50 m, or 3.75 m. These are sizes that allow for easy transport in containers on land or water, as the individual components are also comparatively light. A major advantage is that the raw materials can be easily transported to the construction site for the construction of the floating foundations, e.g., in big bags or barrels. Simple equipment such as mixers and wheel loaders are sufficient for mixing, so that the foundations can be easily manufactured and installed on site. Assembly is not temperature-dependent and can take place at -20 degrees Celsius as well as at +45 degrees Celsius. With a possible load of 400 kg / m2 for low foundations and 800 kg / m2, even houses and cranes can be easily erected on them.

[0033] Structures, i.e. larger floating bodies based on the floating elements according to the invention, can thus be used in a variety of areas. From simple piers for floating operations, the mooring of excursion boats or sailboats, to supply platforms for the offshore industry, to machine carriers for loading and unloading ships or for storing materials, every possible application is conceivable. Furthermore, the floating foundations can be used in seawater, as well as in brackish or fresh water. Finally, they can also be used in moorland areas as observation platforms for visitors. The floating foundations are particularly suitable for the construction of driveways or roads in areas with less stable subsoil, as well as for the construction of bridges or temporary bridges.

[0034] While the description focuses on a floating foundation and floating bodies made of floating foundations, the expert will recognize that the material used, depending on its various designs, also offers other possible uses that are not explicitly excluded from the scope of protection. Other areas of application include, for example, floating residential buildings / accommodations, floating work platforms, floating boat storage (garages), bathing platforms, platforms for floating restaurants, floating foundation slabs in flood zones, etc. Furthermore, use in the construction industry as lightweight concrete for prefabricated house components with integrated insulation is conceivable. The material mix can be produced with or without a plastic / plastic mixture. The lightweight concrete can be provided as degradable lightweight concrete, for example, for renaturation projects.

[0035] Implementation of the invention

[0036] The invention is explained using exemplary embodiments.

[0037] Figure 1 shows a floating foundation according to the invention in a view,

[0038] Figure 2 shows a further floating foundation according to the invention in a view,

[0039] Figure 3 shows a structure consisting of several floating foundations in one view,

[0040] Figure 4 a steel pipe for connecting two floating foundations, and

[0041] Figure 5 shows a composite of floating foundations (floating bodies).

[0042] Figure 1 shows a floating foundation 1 with a surface 2, a long side 3 and a long side 4. Hollow spaces 5 extend across the entire width of the floating foundation 1, with the hollow spaces 5 on the long side 3 being arranged lower than the hollow spaces 5 on the long side 4. Coupling elements (not shown here) can be passed through these hollow spaces 5 when assembling several floating foundations 1. The floating foundations 1 are provided with bevels 6 on the edges to facilitate handling, transport and assembly. Figure 2 shows another embodiment of a floating foundation 1 which has a higher load-bearing capacity. The long side 3 and the long side 4 now have a higher number of hollow spaces 5 so that a larger number of coupling elements can be used to ensure the higher loads.Otherwise, the design corresponds to the embodiment according to Fig. 1.

[0043] The structure shown in Fig. 3 is a floating body 7 formed from a plurality of floating elements 1. These are connected to each other by coupling elements 8 in both the transverse and longitudinal directions.

[0044] Figure 4 shows a steel pipe 9 for connecting two floating foundations 1. The steel pipe 9 for connecting two floating foundations 1 has a trapezoidal thread 10 on both sides for connecting two steel pipes 9 for connecting two floating foundations 1 or a steel pipe 9 for connecting two floating foundations 1 and an end pipe 12. A centrally mounted steel profile serves as an attachment point 11 for a hook wrench.

[0045] Figure 5 shows a floating body which is a composite of floating foundations

[0046] I. Here, two floating foundations 1 are connected by means of two steel pipes 9 for connecting two floating foundations 1. An application point

[0047] II for a hook wrench is located between two floating foundations 1 and is used to create a connection between two steel pipes 9 for connecting two floating foundations 1 via the trapezoidal thread 10.

[0048] Likewise, a T-profile-like sheet 13 is arranged between two floating foundations 1, which secures the floating foundations 1 against twisting. For this purpose, the floating foundations 1 can be connected to each other, for example, by screwing, using eyelets on the T-profile-like sheet 13. A rope-like connection between individual floating foundations 1 is also conceivable. This is particularly useful if the eyelets protrude beyond the floating foundations 1, as in the exemplary embodiment shown in Figure 5.

[0049] At the end of the floating body, an end pipe 12 with a trapezoidal thread 10 is attached. The end pipe 12 is connected to a steel pipe 9 for connecting two floating foundations 1 by means of the trapezoidal thread 10. For this purpose, the end pipe 12 has an attachment point 11 for a hook wrench at one end. Furthermore, the end pipe 12 has a

[0050] Screw lock 14 to prevent the pipe connection from loosening.

[0051] List of reference symbols

[0052] 1 Floating foundation

[0053] 2 Surface 3 Long side

[0054] 4 short side

[0055] 5 Cavity

[0056] 6 phase

[0057] 7 Float 8 Coupling element

[0058] 9 Steel pipe for connection

[0059] 10 trapezoidal threads

[0060] 11 Hook wrench attack point

[0061] 12 Tailpipe 13 T-profile similar sheet metal

[0062] 14 Screw locking

Claims

Patent claims 1. Floating foundation 1 comprising an inflated mineral material, namely an inflated altered volcanic glass, and additives, namely water and cement as well as at least one fibrous additive and / or silanes, wherein water is contained in a mass fraction of 5 to 20 percent, Cement is contained in a mass fraction of 5 to 20 percent, the proportion of at least one fibrous additive is a maximum of 23 percent by mass and the proportion of silanes is a maximum of 1 percent by mass.

2. Floating foundation according to claim 1, further comprising a plastic or plastic mixture.

3. Floating foundation 1 according to claim 1 or 2, characterized in that the at least one fibrous additive is fluff.

4. Floating foundation 1 according to one of the preceding claims, characterized in that an outer coating is applied to the floating foundation 1.

5. Floating foundation 1 according to one of the preceding claims, characterized in that the floating foundation 1 has coupling elements 8 on all vertical side surfaces, wherein the coupling elements 8 are designed such that they can be coupled to corresponding coupling elements 8 on other floating foundations 1.

6. Floating foundation 1 according to claim 5, characterized in that the coupling elements 8 have a steel pipe 9 for connecting two floating foundations 1, wherein the jet pipe 9 has a trapezoidal thread 10 on both sides and a steel profile in the middle, which serves as an engagement point 11 for a hook wrench.

7. Floating foundation 1 according to one of the preceding claims, further comprising at least one pipe-fixed threaded anchor, wherein the at least one pipe-fixed threaded anchor comprises a pipe running horizontally in the floating foundation 1, wherein the horizontally running pipe is connected to a vertically running steel rod is connected, wherein the vertically extending steel rod has a threaded pipe section which terminates with a surface 2 of the floating foundation 1.

8. Floating foundation 1 according to one of the preceding claims, characterized in that the floating foundation 1 is designed such that the dead weight is balanced by the load-bearing capacity and the reserve load-bearing capacity.

9. Floating foundation 1 according to one of the preceding claims, characterized in that the floating foundation 1 is non-combustible.

10. Floating foundation 1 according to one of the preceding claims, characterized in that the floating foundation 1 has a very high compressive strength.

11. Floating foundation 1 according to one of the preceding claims, characterized in that the floating foundation 1 does not absorb water.

12. Floating body made of floating foundations 1, characterized in that at least two floating foundations 1 according to claim 1 are coupled to form larger units by means of coupling elements 8.

13. A method for producing a floating foundation 1 according to claim 1, characterized in that first an altered, volcanic glass is expanded in a temperature range of 800 to 1000 degrees Celsius, then the portion with a predetermined maximum grain size is filtered out, the filter result is mixed with the additives water and cement and at least one fibrous additive and / or silanes and / or a plastic / plastic mixture and the mixture is placed in a mold to harden before the hardened floating foundation is subjected to a surface treatment.

14. A method for producing a floating foundation 1 according to claim 13, characterized in that before the mixture is introduced into the mold, hollow bodies are inserted into the mold in such a way that cavities are formed in the floating foundation 1.

15. A method for producing a floating foundation 1 according to claim 13 or 14, characterized in that the floating foundation 1 is provided with holes passing through the floating foundation 1 after or before the surface treatment. *****

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