Elongated member, method of construction thereof, and device thereof

Abstract

The present invention relates to an elongated member and methods of forming and assembling the same, the elongated member being comprised of a stacked sequence of adjacent sections, the elongated member comprising, at each interface of the adjacent sections, a lower sheet member of an upper one of the adjacent sections and an upper sheet member of a lower one of the adjacent sections, the upper and lower sheet members being match-cast as sheet member pairs at each interface and seated relative to each other in the same relative positions as the sheet member pairs were match-cast.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present invention relates to elongated members, construction apparatus and methods thereof for use in a variety of structural applications, including but not limited to wind tower construction, tunnel construction, and pipe construction. [Background technology]

[0002] Towers, tunnels, columns and other long structures are often used on construction sites. For example, a tall concrete tower may be constructed using multiple precast concrete members that are cast at ground level and then lifted into place with a crane or lifting device and assembled to form the long members that form the main portion of the tower. There are two common design approaches to constructing circular concrete towers: a) one that uses stacked precast concrete rings or cylinders, and b) one that uses stacked precast semicircular segments that are assembled.

[0003] Typically such towers are cylindrical and therefore have parallel walls, but towers may also be constructed with tapered, semi-conical, frusto-conical, or parabolic walls when viewed in vertical section. If the geometry varies along its height, multiple precast elements of the tower may require dedicated formwork. Thus, multiple formwork sections may be required to create a precast tower section, which can be expensive.

[0004] The process of creating a precast concrete ring or cylinder may involve a vertically standing formwork that defines an inner and outer form between which a concrete slurry is poured and then allowed to harden to define a hollow concrete ring or cylinder. The hydrostatic pressure that builds up during the pouring of the slurry can be very large depending on the height of the pour. Such pressure can be resolved by using form ties or by using bands around the outer form using hoop tensioning. The inner form may also be suitably reinforced to withstand the pressure generated by the poured concrete.

[0005] It is desirable to produce taller concrete rings or cylinders because it means fewer units need to be manufactured and processed to assemble a tower of a particular height, saving on construction costs. However, a disadvantage of tall vertically cast concrete rings or cylinders is that the formwork used to create such rings or cylinders must be designed to accommodate high hydrostatic loads, which can be costly. The installation of formwork ties made to accommodate the forces can lead to high labor costs and can leave formwork tie holes in the walls of the ring or cylinder.

[0006] Not only must hydrostatic design parameters be considered, but handling and possibly transportation of the precast components of the tower also place limitations on the size of the precast rings, cylinders, or segments that can be created. Cranes may have limited lifting capacity to handle the tower components being assembled, and therefore the total weight of the components may be limited by such factors. While it may be theoretically feasible to create a tower from a single precast element, hydrostatic pressures, handling and transportation limitations, and construction costs may all affect limitations on what is possible or desirable to create a tower or other elongated elements such as pipes or tunnels.

[0007] It is often desirable to also match-cast subsequent tubes to improve the subsequent assembly / stacking process, but doing so introduces another drawback of these known methods of creating concrete rings or cylinders, in addition to the cost, labor, and technical limitations mentioned above: the time it takes to assemble a complete series of match-cast tubes.

[0008] For example, in such a method, the first tube is cast, then a form for casting the next tube is assembled over the first cast tube, and the interface joint is match cast. After the concrete has hardened, the second tube can be raised, isolating the match cast interface. Then more formwork is installed over the second tube, and a third tube formwork is assembled. Once the third tube is cast, it is lifted, formwork is assembled over it, and the next tube is poured, and the same sequence is repeated until a sufficient number of tubes have been produced.

[0009] Casting match-cast tubes in this manner takes time, taking around 24 hours for the concrete to gain enough strength to be able to move it from its casting location; therefore, casting is limited to around one tube per day. For example, to build the tubes needed for a 150 metre tall tower, 30 tubes, each 5 metres tall, would be needed, which may take around a month to manufacture. Thus, the speed at which match-cast tubes can be cast using this method is limited by the time it takes for the concrete to gain strength to allow the tubes to be handled and lifted.

[0010] Formwork costs for a precast semicircular segment approach can be lower than a precast ring or cylinder. However, precast semicircular segments require grouted connections between each segment during assembly of the tower, which can be costly. The grouted connections can be established by a viscous hardening liquid, usually cement-based, used to bond the two precast elements together. Reinforcement is usually used in and across the joints to achieve structural continuity between the precast elements. The increased number of parts required to assemble the tower increases material and labor costs, including during construction.

[0011] References made herein to patents, other external documents, or other sources of information are generally for the purpose of providing a background for discussing features of the present invention. Unless specifically stated otherwise, a reference to such external documents or such sources shall not be construed as an admission that such documents or such sources are prior art or form part of the common general knowledge in the art in any jurisdiction.

[0012] It is an aim of at least preferred embodiments of the present invention to ameliorate at least some of the above-mentioned shortcomings of known precast tube or section forming methods and / or to at least provide the general public with a useful alternative. Summary of the Invention

[0013] According to a first aspect of the present invention there is provided an elongate member comprising a stacked sequence of adjacent sections, the elongate member comprising: At each interface of adjacent sections, (a) a lower sheet member of an upper one of said adjacent sections; (b) an upper sheet member in a lower one of the adjacent sections; The upper sheet member and the lower sheet member are match-cast at each of the interfaces as the sheet member pairs and seat together in the same relative positions as the sheet member pairs were match-cast.

[0014] In a second aspect of the present invention there is provided an elongate member comprising a stacked sequence of adjacent sections, the elongate member comprising: At each interface of adjacent sections, (a) a lower sheet member of an upper one of said adjacent sections; (b) an upper sheet member in a lower one of the adjacent sections; The upper and lower sheet members are match-cast at each interface as a sheet member pair prior to stacking, and seated relative to one another in the same relative positions as when the sheet member pairs were match-cast.

[0015] Preferably, each of said portions, each section further comprises an intermediate segment spanning between the respective upper and lower sheet members.

[0016] Preferably, the middle segment of each section is made of a cast hardenable material.

[0017] Preferably, the intermediate segment of each section is made of a cast hardenable material which conforms to the respective upper and lower sheet members.

[0018] Preferably, the segments of each section are constructed from hardened concrete poured across between the respective upper and lower sheet members of that section.

[0019] Preferably, each sheet member pair includes a lower sheet member and an upper sheet member formed by casting the upper sheet member of each sheet member pair onto its lower sheet member by introducing a hardenable material into a sheet member form.

[0020] Preferably, each pair of sheet members comprises a lower sheet member and an upper sheet member, the lower sheet member and the upper sheet member being: i. casting a lower sheet member of each of a plurality of sheet member pairs by introducing a hardenable material into a sheet member form; ii. Casting the upper sheet member of each of the sheet member pairs onto the cast lower sheet member by introducing a hardenable material into the sheet member form.

[0021] Preferably, the match cast surfaces of the upper sheet member and the lower sheet member of each sheet member pair are formed at the interface therebetween so that the upper sheet member and the lower sheet member of each sheet member pair can abut and seat against one another.

[0022] Preferably, the sections are formed to have a hollow cross section.

[0023] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0024] Preferably, the cast hardenable material comprises concrete.

[0025] Preferably, the cast hardenable material is constructed of high slump concrete or self-compacting concrete.

[0026] Preferably, the intermediate segment and / or the sheet member have a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0027] Preferably, the height of said sections is between about 2m and 6m.

[0028] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0029] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 6 meters.

[0030] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0031] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0032] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0033] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongue and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0034] In a second aspect of the present invention, there is provided a long tower assembled by stacking a plurality of sections, the tower being composed of at least two adjacent sections, the at least two adjacent sections including, at their interface, a first sheet member of a first one of the adjacent sections and a second sheet member of a second one of the adjacent sections, the first sheet member and the second sheet member being match-cast as the sheet member pair at the interface, and the sheet member pair being seated against each other in the same relative position as they were match-cast.

[0035] Preferably, the first of the adjacent sections is match cast to the first sheet member and includes a cast intermediate segment projecting longitudinally from the first sheet member.

[0036] Preferably, the second of the adjacent sections is match cast to the second sheet member and includes a cast intermediate segment projecting longitudinally from the second sheet member.

[0037] Preferably, the sections are formed to have a hollow cross section.

[0038] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0039] Preferably, the cast hardenable material comprises concrete.

[0040] Preferably, the cast hardenable material comprises high slump concrete or self-compacting concrete.

[0041] Preferably, the section, its intermediate segment and / or the sheet member are provided with a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0042] Preferably, the height of said sections is between about 2 meters and about 6 meters.

[0043] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0044] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 6 meters.

[0045] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0046] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0047] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0048] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongues and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0049] In a third aspect of the invention, there is provided a method of assembling a plurality of sequentially arranged longitudinally abutting sections of an elongated member (e.g. to define at least part of a tower, pipe or tunnel), the method comprising: a. providing a plurality of sheet member pairs, each pair including a lower sheet member and an upper sheet member; i. forming the upper sheet member of each of said sheet member pairs by casting it over its lower sheet member by introducing a hardenable material into a sheet member form such that match cast surfaces of the upper and lower sheet members of each sheet member pair are formed at the interface therebetween and such that the upper and lower sheet members of each sheet member pair are able to seat against one another; b. separating the upper sheet member from the lower sheet member of each of the sheet member pairs; c. placing a plurality of section forms, wherein for each section form, the upper sheet member of the pair of sheet members is placed on its bottom and the lower sheet member of the subsequent pair of sheet members is placed on its top; d. forming a plurality of sequential sections by casting an intermediate segment between the lower sheet member and the upper sheet member of each of the section forms and introducing a hardenable material therein; e. arranging the sequentially ordered sections in a sequence such that the match cast surfaces of each pair of sheet members are rejoined and seated against one another to define the elongated member.

[0050] Preferably, the method further comprises the step of casting the lower sheet member of each of the plurality of sheet member pairs by introducing the hardenable material into the sheet member form.

[0051] Preferably, the method further comprises, immediately prior to step (i), casting the lower sheet member of each of the plurality of sheet member pairs by introducing a hardenable material into the sheet member form.

[0052] Preferably, the sections are formed to have a hollow cross section.

[0053] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0054] Preferably, the cast hardenable material comprises concrete.

[0055] Preferably, the cast hardenable material comprises high slump concrete or self-compacting concrete.

[0056] Preferably, the section, its intermediate segment and / or the sheet member are provided with a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0057] Preferably, the height of said sections is between about 2 meters and about 6 meters.

[0058] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0059] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 6 meters.

[0060] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0061] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0062] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0063] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongue and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0064] In a fourth aspect of the invention there is provided a method of assembling an elongate member (e.g. to define at least part of a tower, pipe or tunnel) from a plurality of sequentially arranged sections arranged in abutting relation along the length of the elongate member, the method comprising: a. providing a plurality of pairs of sheet members each comprising a lower sheet member and an upper sheet member with a match cast surface at an interface between the sheet members for seating against one another; b. placing a plurality of section forms, wherein for each section form, the upper sheet member of the pair of sheet members is placed on its bottom and the lower sheet member of the subsequent pair of sheet members is placed on its top; c. forming a series of sequential sections by casting an intermediate segment between the lower sheet member and the upper sheet member of each of the section forms and introducing the hardenable material therein; d. arranging the serialized match cast sections in a serialized sequence to define an elongated member such that the match cast surfaces of each of the plurality of sheet member pairs are rejoined and seated against each other to define the elongated member.

[0065] Preferably, the sections are formed to have a hollow cross section.

[0066] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0067] Preferably, the cast hardenable material comprises concrete.

[0068] Preferably, the cast hardenable material comprises high slump concrete or self-compacting concrete.

[0069] Preferably, the section, its intermediate segment and / or the sheet member are provided with a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0070] Preferably, the height of said sections is between about 2 meters and about 6 meters.

[0071] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0072] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 6 meters.

[0073] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0074] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0075] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0076] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongue and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0077] In a fifth aspect of the present invention, there is provided a section of an elongate member (e.g. for defining at least part of a tower, pipe or tunnel) comprising a series of said sections arranged in abutting relation along the longitudinal direction of the elongate member, said section comprising: an intermediate segment formed by introducing a hardenable material into a gap in the sectional form defined between a lower sheet member and an upper sheet member disposed within and / or at an opposite end of the sectional form, said sheet members forming a part of a section when said intermediate segment is hardened; The lower sheet member and the upper sheet member each have an outwardly facing match cast surface configured to seat in abutment with a corresponding outwardly facing match cast surface of the sheet member of another section or sections of the series of sections, the outwardly facing match cast surfaces thereby defining opposite ends of the sections to enable continuous abutment with another section or sections of the series of sections.

[0078] Preferably, the sections are formed to have a hollow cross section.

[0079] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0080] Preferably, the cast hardenable material comprises concrete.

[0081] Preferably, the cast hardenable material comprises high slump concrete or self-compacting concrete.

[0082] Preferably, the section, its intermediate segment and / or the sheet member are provided with a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0083] Preferably, the height of said sections is between about 2 meters and about 6 meters.

[0084] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0085] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 6 meters.

[0086] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0087] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0088] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0089] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongue and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0090] In a sixth aspect of the present invention, there is provided a method of casting a plurality of pairs of sheet members, each pair including a lower sheet member and an upper sheet member, for assembling an elongate member comprising a plurality of sequentially arranged sections arranged in abutting relation along the length of the elongate member, the method comprising: i. casting the lower sheet member of each of the plurality of sheet member pairs by introducing a hardenable material into a sheet member form; ii. casting each upper sheet member of each said sheet member pair onto the cast lower sheet member by introducing a hardenable material into the sheet member form so that match cast surfaces of the upper sheet member and the lower sheet member of each said sheet member pair are formed at the interface therebetween and the upper sheet member and the lower sheet member of each said sheet member pair can seat in abutment against one another.

[0091] Preferably, the method further comprises the step of separating the upper sheet member from the lower sheet member of each said pair of cast sheet members.

[0092] Preferably, the sections are formed to have a hollow cross section.

[0093] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0094] Preferably, the cast hardenable material comprises concrete.

[0095] Preferably, the cast hardenable material comprises high slump concrete or self-compacting concrete.

[0096] Preferably, the section, its intermediate segment and / or the sheet member are provided with a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0097] Preferably, the height of said sections is between about 2 meters and about 6 meters.

[0098] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0099] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 6 meters.

[0100] Preferably, the lowermost of said section of the stack defining at least part, preferably the majority, of the wind tower is supported on a foundation.

[0101] Preferably the foundation is a concrete piling or block.

[0102] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0103] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0104] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0105] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongue and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0106] In a seventh aspect of the present invention there is provided a method of constructing an elongate member from a plurality of abutting sections, said method comprising the steps of: a. forming a first sheet member by casting the curable material against the second sheet member to define a match cast surface of each of the first sheet member and the second sheet member at an interface between the first sheet member and the second sheet member; b. forming a first one of the sections by match-casting a first section segment against the first sheet member and projecting the first section segment longitudinally away from the first sheet member, the match-cast surface of the first sheet member appearing at a first end of the first section; c. forming a second one of the sections by match-casting a second section segment against the second sheet member using a hardenable material and projecting the second section segment longitudinally away from the second sheet member, the match-cast surface of the second sheet member appearing at a first end of the second section; and d. stacking the first section against the second section such that the match cast surface of the first sheet member abuts the match cast surface of the second sheet member.

[0107] Preferably, the first sheet member is formed by casting a curable material onto the second sheet member.

[0108] Preferably, a first of the sections is formed by match-casting a first section segment onto the first sheet member using a hardenable material and projecting the first section segment longitudinally downwardly away from the second sheet member, the match-cast surface of the first sheet member emerging at a first end, which is the lower end, of the first section.

[0109] Preferably, a second of the sections is formed by match-casting a second section segment onto the second sheet member using a hardenable material and projecting the second section segment longitudinally downwardly away from the second sheet member, the match-cast surface of the second sheet member emerging at a first end, which is the lower end, of the second section.

[0110] Preferably, a second of the sections is formed by match-casting a second section segment against the second sheet member using a hardenable material and projecting the second section segment longitudinally downwardly away from the second sheet member, the match-cast surface of the second sheet member emerging at a first end, which is an upper end, of the second section.

[0111] Preferably, said stacking is vertical.

[0112] Preferably, the sections are formed to have a hollow cross section.

[0113] Preferably the section is cylindrical, preferably tubular, so that the cross-sectional shape of the periphery is generally circular.

[0114] Preferably, the cast hardenable material comprises concrete.

[0115] Preferably, the cast hardenable material comprises high slump concrete or self-compacting concrete.

[0116] Preferably, the section, its intermediate segment and / or the sheet member are provided with a hollow interior so as to present a generally annular peripheral cross-sectional shape.

[0117] Preferably, the height of the section(s) is between about 2 metres and about 6 metres.

[0118] Preferably, the height of the upper sheet member and / or the lower sheet member is between about 500 mm and 2 meters.

[0119] Preferably, the lateral span or diameter of the section, its intermediate segment, and / or the sheet member is between about 2 meters and about 10 meters.

[0120] Preferably, the lower sheet member of each section includes rebar extending upwardly therefrom to the intermediate segment and / or upper sheet member of that section.

[0121] Preferably the top sheet member of each section is provided with holes arranged to receive said rebars.

[0122] Preferably, the upper sheet member of each section is provided with holes constructed as conduits for introducing said cast hardenable material during formation of the lower sheet member of the respective sheet member pair and / or during formation of the intermediate segment of said section.

[0123] Preferably, the interface between the upper and lower sheet members of each pair of sheet members is formed with openings and / or tongue and groove structures corresponding to castellations in the match cast surfaces of the sheet members, and these structures are configured to cooperate with each other when the sheet members are seated against each other.

[0124] In a further aspect, the invention may be described as a tower constructed of a plurality of sections stacked on top of one another, where at the interface of each section the match cast sheet members abut one another in the same relative orientation as they were previously match cast.

[0125] Preferably, the section is as described above.

[0126] Preferably the sheet member is as described above.

[0127] Preferably the sections are stacked to a height of more than 30m, preferably more than 60m, preferably more than 80m.

[0128] In a further aspect, the invention can be said to be a tower comprised of a plurality of sections as previously described herein.

[0129] Preferably the stack is vertical.

[0130] Preferably the stack is horizontal.

[0131] Preferably, the stack is rectilinear.

[0132] Preferably, the stack is curved (eg in the form of a tunnel or pipe).

[0133] The term "comprising" as used in the present specification and claims means "consisting at least in part of." When interpreting statements in the present specification and claims containing the term "comprising," there may be more features present than the feature preceded by that term in each statement. Related terms such as "comprising" and "included" are to be interpreted in the same manner.

[0134] Reference to a numerical range disclosed herein (e.g., 1-10) also incorporates reference to every rational number within that range (e.g., 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9, and 10) and any rational number range within that range (e.g., 2-8, 1.5-5.5, and 3.1-4.7), such that every subrange of every range explicitly disclosed herein is expressly disclosed herein. These are merely examples of what is specifically intended, and all possible combinations of numerical values ​​between the lowest and highest values ​​recited are to be considered as being expressly set forth in this application in a similar manner.

[0135] The present invention may also include the parts, elements and features referred to or indicated herein, individually or collectively, and any or all combinations of any two or more of such parts, elements or features, and where specific integers referred to herein have known equivalents in the art to which the present invention pertains, these known equivalents are deemed to be incorporated herein as if set forth separately.

[0136] As used herein, the term "(s)" following a noun refers to the plural and / or the singular form of that noun.

[0137] As used herein, the term "and / or" means "and" or "or," or both, where the context permits.

[0138] The present invention comprises the above and also contemplates the following constructions, of which the following are examples only: [Brief description of the drawings]

[0139] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 illustrates a perspective view of an embodiment of an elongate member formed by the successive abutment of sequentially arranged sections. [Figure 2A] 1 shows a perspective exploded view of a section of an embodiment formed from the methods and apparatus described herein. [Figure 2B] 1 shows a perspective exploded view of a section of another embodiment formed from the methods and apparatus described herein. [Figure 3A] FIG. 2 shows a cross-sectional side view of a sheet member form according to an embodiment. [Figure 3B] FIG. 13 shows a cross-sectional side view of an embodiment of a sheet member form with a lower sheet member cast thereon. [Figure 3C] 1 shows a cross-sectional side view of an embodiment of a sheet member form in which a lower sheet member and an upper sheet member are cast. [Figure 4A] 1 shows a cross-sectional side view of two embodiments of sheet member forms with sheet member pairs formed thereon. [Figure 4B] 4B shows a cross-sectional side view of the lower sheet member of the pair of sheet members of FIG. 4A that has been repositioned to the upper layer. [Figure 4C] 4C shows a cross-sectional side view of a two-section form having two sections formed with the bottom sheet member of FIG. 4B. [Figure 4D]FIG. 4D shows a cross-sectional side view of the two completed sections of FIG. 4C lifted into contact with one another. [Figure 5A] FIG. 13 shows a cross-sectional side view of the inner formwork of an embodiment of a section formwork placed on top of a level. [Figure 5B] FIG. 5B shows a cross-sectional side view of the embodiment section form of FIG. 5A with the outer form in place. [Figure 5C] FIG. 5C shows a cross-sectional side view of the embodiment section form of FIG. 5B with the mid-segment limit portion in place. [Figure 5D] 5D shows a detailed cross-sectional side view of a portion of the embodiment section form of FIG. 5C. [Figure 5E] FIG. 5E shows a cross-sectional side view of the section formwork of the embodiment of FIG. 5D in a fully assembled state. [Figure 5F] FIG. 5F shows a cross-sectional side view of the embodiment of FIG. 5E with the section form disassembled to leave the completed section. [Figure 6A] 13A-13C show cross-sectional side views of the inner and outer forms of an embodiment sheet member form being reused as the inner and outer forms of an embodiment section form. [Figure 6B] 13A-13C show side views of an embodiment of a sheet member pair having castellations and openings around the interface. [Figure 6C] 1 illustrates a cross-sectional side view of an embodiment of a sheet member pair having a tongue and groove configuration about their interface disposed within an embodiment of a sheet member form. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0140] ELECTRIC MEMBERS AND METHODS FOR FORMING ELECTRIC MEMBERS FIELD OF THE DISCLOSURE The present invention relates to elongated members, methods and associated apparatus for forming elongated members using hardenable materials such as concrete.

[0141] Elongate members according to embodiments of the invention may be solid or hollow in cross section, and may be formed with either a straight or at least partially non-straight longitudinal configuration. If hollow, they may define a passageway therethrough in the longitudinal direction. In a preferred form, the elongate members are cylindrical, preferably tubular, and thus have a generally circular circumferential cross-sectional shape. However, they may be other shapes, such as prismatic (e.g., polygonal, such as triangular, square, hexagonal, or octagonal, in cross section), and may have corresponding or non-corresponding polygonal, triangular, hexagonal, or octagonal internal circumferential cross-sectional shapes.

[0142] Preferably, the elongate member is hollow with a substantially cylindrical or tapered circular periphery. Preferably, it is manufactured using a hardenable material in a casting process. Thus, the hardenable material may be a castable hardenable material such as pourable concrete. Before solidification, the hardenable material is flowable and can be poured.

[0143] In a preferred form, the elongate member may be defined by a plurality of sections, the sections may have a length that is parallel to the elongate axis when assembled as part of the elongate member, the sections have ends at their ends that may be defined by at least one outwardly facing surface, as described below.

[0144] As the sections are arranged to define the elongated member, they are each cylindrical, preferably tubular, and therefore in some cases may have a generally circular circumferential cross-sectional shape. However, each section may be other shapes, such as prismatic (e.g. polygonal, such as triangular, square, hexagonal, or octagonal in cross-section), and may have corresponding or non-corresponding polygonal, triangular, hexagonal, or octagonal internal circumferential cross-sectional shapes. Such sections are also preferably hollow, having a passageway therethrough and an opposite end. The sections of an elongated member need not all be identical. For example, if the elongated member defines a tower for a wind turbine generator, the tower may be tapered, and thus a section at the top may be smaller in diameter than a section at or near the base of the tower.

[0145] The sections may be formed simultaneously or separately as described herein, or the sections may be formed as a unitary item within a form and then assembled into an elongated member.

[0146] Examples of structures that may be constructed using elongated members that may be formed from the methods and apparatus described herein include, but are not limited to, tower structures, such as onshore or offshore marine tower structures, including those used as wind turbine towers, tower structures such as buildings or skyscrapers, pipes, lengths of underground tunnel structures (i.e. road vehicle transport tunnels), partially or fully submerged marine support structures such as bridge columns, or support columns and structures in general for the construction of various types of buildings or skyscrapers. In the case of tunnels or pipes, the passages defined through the elongated members may provide locations for transportation conduits and utilities. In the case of towers, the passages defined through the elongated members may provide locations for access passages and utilities.

[0147] Thus, while the examples provided herein primarily refer to elongated members and their formation for use in towers, such as wind turbine towers that may be used for land or offshore installations, and certain advantages described herein arise particularly when the methods are employed in the construction of such wind towers, those skilled in the art will appreciate that the disclosure is equally applicable to the construction of a wide variety of structures, and that many of the advantages or benefits described herein in relation to the construction of wind towers are likewise applicable to a wide variety of structures.

[0148] Thus, when the term tower is used throughout this specification, it refers to an elongated portion of a tower, and its functions and features, as well as any methods or means of formation, construction, and assembly, are also applicable to elongated members in other applications as described herein, and therefore the terms tower and elongated member may be used interchangeably throughout this section of the specification.

[0149] An example of such an elongated member 10 is shown in FIG. 1, forming a tower 10 of a wind turbine installation, as shown. The tower 10 includes a number of sequentially arranged sections 20 arranged in abutment with a longitudinal direction X of the elongated member 10 or tower 10. References herein to an elongated axis or direction, whether of the elongated member / tower 10 or of the sections 20 that make it up, refer to a longitudinal direction or axis that runs approximately through the middle of the length of the elongated member 10 or its sections 20. In some applications, such as the wind tower 10 of FIG. 1, this elongated axis or direction X is oriented vertically, corresponding to the upright direction of the corresponding elongated member 10 as installed / placed on site. However, in other applications, such as the tunnels and pipes mentioned above, this elongated axis or direction X may be oriented horizontally, corresponding to the horizontal direction of the corresponding elongated member 10 as installed / placed on site. Of course, it will be appreciated that in some applications the orientation of the elongated members 10 installed on-site will not be substantially vertical or horizontal, but will require something in between, such as an angled elongated member 10 that forms part of the slope of the tunnel / pipe.

[0150] In any event, regardless of the on-site orientation of the elongated member 10 once installed / positioned, its sections 20 will be formed in a vertical orientation by the methods and apparatus described herein. That is, the longitudinal direction X of the sections 20 shown in Figures 1-6C is shown to be vertical, and therefore the sections 20 extend longitudinally in a vertical direction. In some cases, the sections 20 shown and / or described herein are not "elongated" per se (i.e., the sections 20 may be of low aspect ratio, having a height equal to or less than their cross-sectional span / diameter), but their longitudinal axis X will still extend along the sections 20 in a manner that corresponds to the longitudinal / longitudinal direction of the elongated member 10 of which they will ultimately form a part.

[0151] An example section 20 is shown in FIG. 2A, where section 20 and its longitudinal axis X are oriented vertically as previously described. Terms such as "top," "bottom," "higher," and "middle" are used herein with respect to the sides of section 20 to merely indicate their relative vertical positions in the vertical direction during formation of section 20 or its building blocks. However, these terms should be construed in a descriptive manner only and may or may not represent the relative vertical positions of the sides of section 20 during assembly or after assembly / installation as part of a larger elongated member 10.

[0152] Section 20 is shown in FIG. 2A in an exploded construction for ease of reference, and may consist primarily of a central intermediate segment 30, an upper sheet member 40 thereover, and a lower sheet member 50 therebelow. Section 20 and its constructed parts are shown in FIGS. 1-6C as being of substantially tubular construction (i.e., cylindrical with a corresponding internal hollow passage therethrough, corresponding to the exemplary embodiment throughout this specification of elongated member 10 used as part of a wind tower).

[0153] However, as explained above, depending on the desired shape of the elongated member 10, the sections 20 can take on a variety of other shapes, such as prismatic (e.g., polygonal in cross section, such as triangular, square, hexagonal, octagonal, etc.), and may have corresponding or non-corresponding polygonal, triangular, hexagonal, or octagonal internal peripheral cross-sectional shapes / hollow passages. Depending on the application of the elongated member 10, a hollow internal passage may or may not be required, and may or may not be tapered along its length, thus requiring the sections 20 to be similarly tapered along their vertical lengths, regardless of whether or not they have an internal hollow passage. Additionally, some sections 20 may have internal peripheral cross-sectional shapes / hollow passages that are different in shape from and do not correspond to the external peripheral cross-sectional shape. It is contemplated that multiple hollow passages may be provided.

[0154] In either case, the central intermediate segment 30, upper sheet member 40, and lower sheet member 50 of section 20 shown in Figures 1-6C preferably have a longitudinally consistent (non-tapered) substantially tubular / cylindrical construction, with the outer periphery 32 of the intermediate segment, the outer periphery 42 of the upper sheet member, and the outer periphery 52 of the lower sheet member preferably being equal in diameter, and the inner periphery 34 of the intermediate segment, the inner periphery 44 of the upper sheet member, and the inner periphery 54 of the lower sheet member also preferably being equal in diameter.

[0155] The intermediate segment 30 has an upper surface 30A and a lower surface 30B that define the planes of the opposite ends of the intermediate segment 30. The upper surface 30A is configured to abut and cooperate with the lower surface 40B of the upper sheet member 40, and the lower surface 30B is configured to abut and cooperate with the upper surface 50A of the lower sheet member 50. The sheet members 40, 50 also have upper and lower surfaces 40A, 50B that define outwardly facing match cast surfaces. That is, the upper sheet member 40 has an upper surface 40A, hereinafter referred to as the upper match cast surface 40A, and the lower sheet member 50 has a lower surface 50B, hereinafter referred to as the lower match cast surface 50B. These match cast surfaces 40A, 50B face outward in the sense that they define the opposite ends of the section 20 (the "upper" opposite end 20A and the "lower" opposite end 20B).

[0156] The intermediate segment 30 is preferably formed by introducing a hardenable material into a gap 202 of the section form 200 defined between a lower sheet member 50 and an upper sheet member 40 disposed within the section form 200, as described in more detail below, such that when the intermediate segment 30 is hardened, the sheet members 40, 50 form part of the section 20. Furthermore, the outwardly facing match cast surfaces 40A, 50B of the sheet members 40, 50 are configured to seat in abutment against a corresponding outwardly facing match cast surface of another section or sheet member of the series of sections forming the elongated member 10. In this manner, the outwardly facing match cast surfaces 40A, 50B define opposite ends 20A, 20B of the section 20, allowing the section 20 to abut continuously against another section or sections of the series of sections.

[0157] The sheet members 40, 50 themselves are formed by introducing a hardenable material into a sheet member form 100 to form a pair of sheet members 101, as will be described in more detail below, and for the upper sheet member 140 and the lower sheet member 150, this formation also occurs vertically.

[0158] However, the sheet members 40, 50 of any section 20 are not formed together, but are derived from two different match cast sheet member pairs 101 that are match cast together and then split / separated. Thus, the lower sheet member 50 of section 20 is actually derived from the upper sheet member 140 of the first sheet member pair 101A, and the upper sheet member 40 of section 20 is actually derived from the lower sheet member 150 of the second sheet member pair 101B.

[0159] This becomes clear by reference to a method of forming a sheet member form 101, as shown in Figures 3A-3B, in which a cross-sectional view of a sheet member form 100 during a forming process is shown, the cross-section being taken through a vertical plane extending substantially along the longitudinal axis X.

[0160] 3A shows the sheet member form 100 before the hardenable material is introduced, showing an inner form member 102 and an outer form member 104, both of which are substantially cylindrical / tubular annular members that define inner and outer perimeters 144, 146, 154, 156 of the sheet member to be formed therebetween. It will be understood that these inner and outer form members 102, 104 may be of other shapes / constructions depending on the desired inner and outer cross-sectional shape, diameter, taper, etc. of the sheet member to be formed therefrom.

[0161] The inner and outer formwork members 102, 104 are positioned on a formwork level 60 and are configured to provide as accurate a level as possible for the subsequent formation of the sheet member pair 101. Also shown in Figure 3A is an interface 109 that defines an imaginary abutment between the lower sheet member 150 and the upper sheet member 140 of the sheet member pair 101. This interface is formed by introducing a hardenable material into the sheet member formwork 100.

[0162] The hardenable materials referred to herein are castable hardenable materials, such as pourable concrete, and are preferably fluid so that they can be introduced by pouring, pouring / pumping, or other means known in the art for propelling or introducing such hardenable materials. The preferred type of concrete used is "high slump" or self-compacting concrete. Self-compacting concrete is very easy to transport after pre-curing, and automatically levels when poured into the forms 100, 200 described herein.

[0163] During casting, the outer form 104 supports the casting pressure as an initial load of hardenable material is injected into the void to form the first, or bottom, lower sheet member 150. Once the sheet member 150 has sufficiently hardened and acquired sufficient strength, as shown in FIG. 3B, a release agent may be applied to the "top" surface (corresponding face 150A) of the sheet member 150, and then more hardenable material may be injected into the void to form the second sheet member 140 thereon, as shown in FIG. 3C. The release agent prevents the two sheet members 140, 150 from sticking or bonding to each other, and the lower sheet member 150 acts as a "proformer" for the second sheet member 140 poured therein, creating a match cast fit along the interface 109.

[0164] This match cast fit provides outwardly facing match cast surfaces 140B, 150A of the sheet members 140, 150 that allow the sheet members 140, 150 to sit against one another. Once the sheet members 140, 150 are formed and secured, they can be separated and the top sheet member 140 is used to form the "lower" sheet member 50 of the first section 20 (which defines its lower opposite end 20B) and the bottom sheet member 150 is used to form the "upper" sheet member 40 of the second section 20 (which defines its upper opposite end 20A). Once formed, the sections can be joined by assembling the first section over the second section (for elongated members 10 that are vertically oriented in the field) so that the match cast surfaces 140B correspond to, match and connect with the match cast surfaces 150A.

[0165] In this manner, the matching cast fit along the interface 109 during casting of the sheet member pair 101 provides the aforementioned advantage of easily joining successive sections 20 when assembling a larger elongated member 10 or portion thereof (i.e., one section can be abutted successively with another section or section of a series of sections). In this manner, the match cast surface 140B of the top sheet member of a given sheet member pair 101 may be considered to be "negative" as opposed to the match cast surface 150A of the bottom member of the same sheet member pair 101 being "positive". Final rejoining after forming portions of the two distinct sections (i.e., after defining the opposing top and bottom ends 20A and 20B of the two distinct sections) also brings their "negative" and "positive" "polarities" together again, allowing for effective load transfer between them.

[0166] 3C, reinforcing bars 148, or rebars, are shown extending upward from the top sheet member 140, starting from a location near the match cast surface 140B of the sheet member 140 and extending outwardly through the top surface 140B of the sheet member 140. These rebars 148 can be used to reinforce or strengthen the sheet members, and also serve to increase the tensile resilience of the entire section 20, as the rebars 148 extend into the area of ​​the section form where the intermediate segments 30 are cast and thus where the hardenable material is injected around the rebars 148.

[0167] The holes 158 are also shown extending through the lower sheet member 150, since the casting of said sheet members is preferably performed on a horizontal surface. When the lower sheet member 150 is separated from the respective sheet member pair 101, it is placed in the sectional formwork 200 as the upper sheet member 40, and the upper sheet member 140 is placed in the sectional formwork 200 as the lower sheet member 50, so that the rebars 148 of the upper sheet member 140 (the lower sheet member 50 placed in the sectional formwork 200) can extend upward through the holes 158 of the lower sheet member 150 (the upper sheet member 40 placed in the sectional formwork 200). In this manner, the positions of the holes 158 and the rebars 148 may be appropriately constructed to correspond to each other.

[0168] The holes 158 may also be used to introduce hardenable material after the lower sheet member 150 is placed into the section form 200 as the upper sheet member 40, which is poured, injected, pumped or otherwise introduced through the holes 158 into the voids of the section form 200 to form the middle segment 30 of the section 20, as will be described in more detail below.

[0169] The rebar 148 may be constructed from steel dowels, or other known suitable metals, metal alloys, or materials that have tensile capabilities that complement their compressive capabilities, such as cast concrete. In some embodiments, it may be desirable for the rebar 148 to be constructed from corrugated bars (and / or dowels with corrugated sleeves) and for the holes 158 to be a larger size (larger diameter) than the rebar 148. This allows for a hardenable material to rise up through the holes and surround the rebar 148, engaging / hardening the corrugations of the rebar 148 as the voids of the section form 200 are filled (i.e., the mid-segment 30 is fully "poured"), further enhancing the resilience and overall integrity of the finished / formed section 20.

[0170] It will be appreciated that in some embodiments, the top sheet member 140 may be formed with a number of rebars 148 (i.e., circumferentially disposed between its inner and outer peripheries 144, 146) which may result in the need for a number of holes 158 in the bottom sheet member 150 (i.e., also circumferentially disposed between its inner and outer peripheries 154, 156). This is shown in FIG. 2B, where the top sheet member 140 is placed as part of a section as the bottom sheet member 50, and the bottom sheet member 150 is placed as part of a section as the top sheet member 40, resulting in the need for a number of rebars 148 and a number of holes 158. It will be noted that FIG. 2B is an exploded view of a section 20 of an embodiment having such a construction, and thus the rebars 148 are shown for illustrative purposes only and do not necessarily have the length / height as shown. Additionally, while only vertical rebar 148 is shown in FIG. 2B and other figures, it will be understood that circumferentially extending horizontal rebar (i.e., annular rings of rebar) are also provided at various points along the height of the vertical rebar 148, thereby forming a reinforcing cage.

[0171] 2B also illustrates that sheet members 40, 50 may be formed with alignment guides or pins 160 extending from the match cast surfaces 40A, 50B to interface with corresponding receptacles formed on corresponding match case surfaces of other co-formed sheet members. These alignment guides or pins 160 may assist in facsimile alignment of sections 20 as they are moved into abutment during assembly of elongated member 10.

[0172] The process of forming the above-mentioned section 20 will now be described below with reference to Figures 4A to 4D. For the sake of explanation, two sheet member pairs 101A1, 101A2 are shown being formed into two sections 20A, 20B. However, as will be described later, this process may also be carried out by advantageously forming multiple sheet member pairs and multiple sections 20 simultaneously.

[0173] In Fig. 4A, a first sheet member pair 101A1 having an upper sheet member 140A1 and a lower sheet member 150A1 is formed on the left side. Similarly, a second sheet member pair 101B2 having an upper sheet member 140A2 and a lower sheet member 140B2 is formed on the right side.

[0174] In Fig. 4B, the forms 100A1, 100B2 of the respective sheet member pairs 101A1, 101B2 are disassembled / removed, the respective sheet member pairs 101A1, 101B2 are separated, and the top sheet member 140B2 of the second right-hand sheet member pair 101B2 is placed on the left-hand level 60A1, while the top sheet member 140C3 of another sheet member pair (the formation of which is not shown in Fig. 4A) is placed on the level 60B2 of the right-hand sheet member pair 101B2.

[0175] In Figure 4C, two sectional forms 200A1, 200B2 are assembled on levels 60A1 and 60A2. The sectional forms 200A1, 200B2 shown in Figures 4C-4D are generalized for illustrative purposes only, and more detailed embodiments or constructions of exemplary sectional forms are shown and described below with reference to Figures 5A-5F.

[0176] Here, the lower sheet member 150A1 of the first sheet member pair 101A1 is placed on top of the first section formwork 200A1 (and therefore becomes the upper sheet member 40A of the section 20A formed therefrom), while the lower sheet member 150B2 of the second sheet member pair 101B2 is placed on top of the second section formwork 200B2 (and therefore becomes the upper sheet member 40B of the section 20B formed therefrom).

[0177] The intermediate segments 30A and 30B are formed by introducing a hardenable material into the space between the sheet members pairs 150A1, 140B2 and 150B2, 140C3 (which may be performed through holes in the sheet members 150A1, 150B2). The assembly of the section forms 200A1, 200B2 and the formation of the intermediate segments are described in more detail below.

[0178] In Fig. 4D, the intermediate segments 30A and 30B are cured and the sections 20A, 20B are fully formed, of which the respective sheet members 150A1, 140B2 and 150B2, 140C3 form part. The section forms 200A1, 200B2 are disassembled and removed. Fig. 4D also shows the completed section 20A being lifted or moved (by a crane or other suitable device) from its ground position and placed on top of the section 20B. Thus, the sections 20A, 20B can be successfully joined together via a match cast fitting between the match cast surface 140B (the upper sheet member 140B2 of the second sheet member pair 101B2) and the corresponding match cast surface 150A (the lower sheet member 150B2 of the second sheet member pair 101B2), which are match cast at the interface 109 during the formation of the second sheet member pair 101B2.

[0179] Although not shown in Figure 4D, alignment guides or pins 160 (as shown and described with reference to Figure 2B above) extending from match cast surfaces 140B, 150A contribute to interfacing sections 20A, 20B. Those skilled in the art will appreciate a wide variety of pins, guides, and other alignment means that can be formed as part of sheet member pair 101 or added to sheet member pair 101 after formation / casting to assist in downstream match cast fitting of surfaces 140B, 150A.

[0180] 4A-4D thus illustrate a main advantage of the method described herein for assembling an elongated member 10 from a plurality of sequentially arranged sections 20 arranged in abutting relation in the longitudinal direction X of the elongated member 10, said method comprising: a. A plurality of sheet member pairs 101, each including a lower sheet member 150 and an upper sheet member 140; i. casting a lower sheet member 150 of each of the plurality of sheet member pairs 101 by introducing a hardenable material into the sheet member form 100; ii. casting an upper sheet member 140 of each of the plurality of sheet member pairs 101 onto the cast lower sheet member 150 by introducing a hardenable material into the sheet member form 100 such that match cast surfaces 140B, 150A of each sheet member 140, 150 are formed at the interface 109 therebetween and the sheet members 140, 150 of each of the plurality of sheet member pairs 101 are seated against each other; b. separating each sheet member 140, 150 of the plurality of cast sheet member pairs 101; c. placing a plurality of section forms 200, where for each section form 200, the upper sheet member 140 of the sheet member pair 101 is placed at its bottom and the lower sheet member 150 of the subsequent sheet member pair 101 is placed at its top; d. introducing a hardenable material between the lower sheet member 140 and the upper sheet member 150 of each section form 200 to cast a plurality of intermediate segments 30, thereby forming a plurality of sequentially arranged sections 20; e. arranging the sequentially arranged sections 20 in a sequence such that the match cast surfaces 140B, 150A of each of the plurality of sheet member pairs 101 are rejoined and seated against each other to define the elongated member 10.

[0181] Thus, the methods described herein may provide significant advantages in turnover, cost savings, and efficiency in assembling match cast sections of elongated member 10.

[0182] For example, whereas existing methods require subsequent casting and stacking of sections (and thus are limited in speed by the time it takes for the concrete to gain sufficient strength to handle and lift each section), this method instead allows all required lower sheet members 150 of the required sheet member pairs 101 to be cast simultaneously on the first day. On the second day, once the lower sheet members 150 have fully set, a release agent may be applied in order to match-cast the corresponding upper sheet members 140 thereon. On the third day, the fully formed sheet member pairs 101 may be separated and placed within the section form 200. By the end of the fourth day, the middle segment 30 of the section 20 is placed (by introducing pre-placeable material between the sheet members placed within the section form 200). Following this, the section form 200 may be disassembled and the completed section 20 may be prepared for transportation, storage, or on-site assembly.

[0183] Thus, all sections 20 required for a particular elongated member can be ready for assembly within one week, compared to one month using known continuous section cast-and-stack methods.

[0184] It will of course be appreciated that in some embodiments, rather than being cast on-site as described above, multiple sheet member pairs 101 (each including a lower sheet member 150 and an upper sheet member 140 including match cast surfaces 140B, 150A that seat against each other at an interface 109 therebetween) can be prepared preformed at a separate location.

[0185] In any case, the ability to produce a large number of sections 20 in a short time allows for a "just on time" manufacturing principle and eliminates the need for large amounts of storage space required to create a large number of sections with known / previous methods. Furthermore, the likelihood of accidents is significantly reduced, as the work is done at ground level (i.e. the assembly of the sheet member formwork 100 and the section formwork 200, and the casting therein, can all be performed at the same level 60), and there are no risks associated with working at height (i.e. lifting / stacking sections with known / previous methods). This reduces the amount of safety risks associated with such projects, reduces the labor / handling required and therefore costs, and also reduces the amount of safety documentation and controls often required for large profile building projects.

[0186] It should further be noted that because a large number of sections 20 can be cast in a short time, the height of the sections 20 can be significantly reduced compared to known serial section cast stacking methods, which require, for example, 5 m high section casts due to long forming times. Thus, the hydrostatic pressure on the section formwork 200 is much lower, since a much smaller amount of hardenable material is introduced in the formation of the intermediate segments 30 of each section 20. Thus, the section formwork 200 described herein can benefit from a much simpler and cheaper design and assembly, since its performance requirements are significantly reduced.

[0187] The height of the sections 20 formed by the methods / apparatus described herein is significantly reduced compared to known continuous section cast stacking methods, and therefore the subsequent handling requirements are also significantly reduced. The cranes or other lifting equipment required to move / store or lift / assemble the sections 20 to the elongated member 10 do not need to be as powerful (weight rated), and therefore the downstream costs associated with transporting, handling, or assembling the sections 20 are also reduced. The same is true for the sheet members and section forms 100, 200, which, as a result of their reduced complexity, are much lighter than the forms required for known continuous section cast stacking methods, thereby reducing the labor and handling costs / time in assembling, dismantling, or moving the sheet members and section forms 100, 200. This also means that more forms can be assembled and more sections 20 can be created in less time.

[0188] An example of assembly of an embodiment of the section formwork 200 will now be described in more detail with reference to Figures 5A-5F.

[0189] In Figure 5A, the top sheet member 140 (now the bottom sheet member 50) of sheet member pair 101 is placed on level 60 (i.e., the one shown in Figure 4B) and then the inner form 202 is placed. This inner form 202 is constructed with vertically oriented posts 202A (to form a reinforcing inner cage) around the inner periphery 54 of the bottom sheet member 50 and horizontally oriented clamps 202B positioned to connect the bottom sheet member 50 to the posts 202A and provide the overall bond and integrity of the inner form 202.

[0190] In FIG. 5B, an outer formwork 204 is positioned outside the periphery of lower sheet member 50, onto which lower sheet member 150 (now upper sheet member 40) is suspended (such as by a crane) and onto which positioning cleats 206 are positioned.

[0191] In FIG. 5C , the intermediate segment limit 208 is positioned between the inner form 202 and the outer form 204, specifically located above the abutments 202C, 204C of the inner form post 202A and the outer form 204 (as shown in FIG. 5D ), configured in length to correspond to the top / upper limits of the inner form 202 and the outer form 204, and appropriately dimensioned to facilitate alignment when the top sheet member 50 is lowered into the form 200.

[0192] In this manner, the inner and outer forms 202, 204, abutments 202C, and intermediate segment boundary 208 are appropriately dimensioned such that the gap 200X (as shown in FIG. 5D) formed therebetween defines the appropriate boundary (inner and outer perimeters 34, 36) of the intermediate segment 30 formed therein by the introduction of the hardenable material.

[0193] Also shown in FIG. 5D is a guide 202D that is positioned at an angle on the post 20A of the inner form 202. Detail A in FIG. 5D shows a plan view of the top sheet member 40 with the cleats 206 angled toward the center. Thus, the suspended top sheet member 40 can be lowered into the void 200X with the cleats 206 interfacing / cooperating with the guides 202D to properly concentrically position the top sheet member 40 as required. Although three cleats 206 are shown in Detail A, any number of cleats 206 may be provided to aid in aligning the top sheet member 40 as it is lowered. Positioning the inner and outer forms 202, 204 above the level 60 also ensures that the vertical heights and positions of the various inner and outer forms 202, 204, mid-segment boundary 208, and top and bottom sheet members 40, 50 are accurate and true.

[0194] 5E, the top sheet member 40 has been lowered fully into place, with the cleats 206 resting on the top horizontal clamps 202B of the inner form 202, with their top surfaces 40A properly aligned with the top and middle segment limits 208 of the inner and outer forms 202, 204. It has also been seen that with the top sheet member 40 properly concentrically positioned (by virtue of the cleats 206 interlocking / cooperating with the guides 202D), the holes 158 in the sheet member and the rebar 148 are also properly aligned with respect to one another. A hardenable material may now be introduced into the void 200X through said holes 158 to form the middle segment 30.

[0195] Once the middle segment 30 is fully set, the section 20 is said to be fully formed in that the upper and lower sheet members 40, 50 form a permanent feature thereof by integral connection with the middle segment 30 cast therebetween and against which they were cast. In FIG. 5F, the inner and outer forms 202, 204 and the middle segment boundary 208 may be disassembled for later removal of the completed section 20.

[0196] In some embodiments, the inner form 102 and the outer form 104 of the sheet member form 100 may be reused as the inner form 202 and the outer form 204 of the section form 200. In such a case, the height of the intermediate segment 30 of the section 20 formed therefrom will be the same or lower than the total height of the sheet member pair 100. This is shown in FIG. 6A, where the inner form 102 and the outer form 104 of the sheet member form 100 are arranged as the inner form 202 and the outer form 204 in the section form 200. The post 202A is still used at the top of the level 60, and when the top sheet member 40 is lowered, its cleat 206 contacts the abutment 202C to ensure that the correct height is achieved as shown by the arrow A1. FIG. 6A shows the top sheet member 40 being lowered for the section form 200. In this section, the height of the void 200X (and therefore the height of the intermediate segment 30 cast therein) is less than the combined height of the sheet member pairs, and therefore less than the heights of the reused inner form 102 (202), outer form 104 (204). Reusing parts of the sheet member form 100 not only saves time and cost, but also has the advantage of reducing the height of the section form 200 (which reduces cost and complexity due to the significant reduction in hydrostatic pressure caused by the amount of hardenable material introduced to form the intermediate segment 30).

[0197] Those skilled in the art will appreciate that other constructions of the sheet members and section forms 100, 200 may be used. The embodiments described above with reference to Figures 3A-3C and 5A-5F are examples of constructions and are used only to illustrate examples of means for properly positioning, dimensioning and reinforcing the sheet members and section forms 100, 200 to form structurally sound sheet member pairs 100 and sections 20. Many other means of formwork assembly are conceivable and known to those skilled in the art that are capable of achieving the intended functions and features described herein.

[0198] Additionally, rebar 148 and holes 158 are provided only as an exemplary construction of sheet members 40, 50 and section 20. Other means may or may not be used to provide internal or external reinforcing elements to section 20. Also, introduction of hardenable material to form intermediate segment 30 may be through means other than holes 158 (such as other vents or openings in sheet members 40, 50 and / or section form 200) or by pumping / injecting upward into void 200X at a point below section form 200.

[0199] In some embodiments, where the sections 20 to be formed are not substantially cylindrical / tubular (i.e., slightly tapered to form a tapered elongate member 10), a flexible section form may be used in which the perimeters of the upper and lower parts of the sections 20 to be formed are defined by movable or reconfigurable inner and outer forms 202, 204. Of course, it will be appreciated that the sheet members and section forms 100, 200 described herein may be shaped or constructed according to the desired outer and inner shape / cross-section / perimeter of the section / sheet member pair to be formed therefrom.

[0200] 2A and 2B show sections 20 in which the height of the intermediate segment 30 is significantly greater than the height of the respective sheet members 40, 50, other embodiment sections may be formed in which the height of the intermediate segment is greater or less than the height of the sheet members. Any suitable ratio may be achieved by the methods described herein depending on the application of a given elongated member.

[0201] FIG. 6B shows an embodiment sheet member pair 101 in which the upper sheet member 140 has castellations 115 around the interface 109 that interlock with corresponding openings 117 in the lower sheet member 150. This can be achieved by reconstructing the sheet member form 100 and method described with reference to FIGS. 3A-3C above. These castellations 115 and corresponding openings 117 will have a sufficient slope or inclination on the protruding surface to allow the sheet members 140, 150 to be released from one another without damage. Annular ribs are envisioned as a method to help secure the members of the pair together. Such keying helps ensure that the rotational alignment of the sheet members is correct and also helps to increase the shear strength generated by the sheet members.

[0202] Alternatively, as shown in Figure 6C, the sheet member pair 101 of the embodiment may be configured such that the top sheet member 140 includes a female groove 119 that cooperates with a corresponding male tongue in the bottom sheet member 150 around the interface 109. In other embodiments, male and female alignment guides or other profiling means around the interface 109 may be envisioned by one skilled in the art to aid in bonding the sheet members of the sheet member pair 101 together.

[0203] The castellations / openings 115, 117, male and female grooves / tongues 119, 120, or other alignment / profiling means around the interface 109 also serve to enable a shear connection between the match cast surfaces 140B, 150A of the sheet member pair 100, providing further integrity when joining the match cast surfaces 140B, 150A of the two sections 20 during assembly of the elongated member 10.

[0204] In some embodiments, the lower sheet member 50 is preformed or pre-placed and placed in the sheet member form 100, and then the upper sheet member 40 is match-cast into the groove, recess, or other receptacle of the preformed lower sheet member 50. In this manner, pre-positioning or pre-molding the lower sheet member without the use of the sheet member form 100 can speed up the typical casting process. That is, by pre-building the lower sheet member off-site and then transporting it and placing the sheet member form 100 around it, downtime during drying is reduced since only the drying time of the upper sheet member 40 needs to be considered. Such a preformed, pre-constructed, or pre-placed lower sheet member 50 can have, for example, a castellated structure as in FIG. 6B, or a tongue and groove as in FIG. 6C, to provide a groove, recess, or other receptacle for receiving / forming the upper sheet member 50, and can be preformed, pre-constructed, or pre-placed from a non-hardening material such as metal.

[0205] The technologist of the present invention may also envision other means of modifying the sheet member forming process described in Figures 3A-3C to speed up the overall construction process. For example, rather than preforming, preconstructing, or pre-placing the lower sheet member 50 from a non-hardening material such as metal in the above embodiment, the lower sheet member 50 may be cast using the sheet member form 100 as normal. However, once dry, the grooves, recesses, or other receptacles of the lower sheet member 50 act as a form for the upper sheet member 40 to be cast therein, so that the sheet member form 100 can be removed from the lower sheet member 50 before or during the casting of the upper sheet member 40 (as said form 100 does not contribute to the casting of said upper sheet member 40). In this manner, the sheet member form 100 can be quickly reused to cast another lower sheet member 50 constructed as described above, speeding up the overall sheet member forming process (as the sheet member form 100 need only be used to cast / place the lower sheet member 50).

[0206] Once the sections 20 have been assembled to form some or all of the elongated member 10, a suitable post-tensioning process known in the art may be employed to help ultimately establish the integrity and connections of the various sections 20 of the elongated member. Post-tensioning means known in the art that may be used include reinforcing means such as cables routed through ducts formed in the sheet members, intermediate segments, etc., or cables located within the hollow interior of the elongated member 10 (i.e., outside the inner perimeter of the sections 20).

Claims

1. An elongated member for a wind tower, the elongated member being composed of a plurality of sections, each section comprising a lower sheet member, an upper sheet member, and an intermediate segment cast vertically between and spanning the upper and lower sheet members; At each interface of adjacent sections, a lower sheet member of the upper one of the adjacent sections; a top sheet member of a lower one of said adjacent sections; The elongated member, wherein the multiple sections are stacked consecutively so that they abut and cooperate to seat together, and the upper sheet member and the lower sheet member are match-cast as a sheet member pair at each of the interfaces.

2. 2. The elongated member of claim 1, wherein the intermediate segment of each of the sections is constructed from hardened concrete poured between the upper and lower sheet members of each of the sections.

3. 2. The elongate member of claim 1, wherein each pair of sheet members is formed by casting an upper sheet member onto a lower sheet member by introducing a hardenable material into the sheet member form.

4. Each pair of sheet members is i. Casting a bottom sheet member by introducing a hardenable material into a sheet member form; ii. Casting an upper sheet member over the cast lower sheet member by introducing a hardenable material into the sheet member form. The elongate member of claim 1 formed by:

5. An elongated member as described in claim 1, wherein the intermediate segments of each section are formed by introducing a hardenable material into a void in the section formwork, the void being defined between respective upper and lower sheet members of the section arranged vertically inside the section formwork and / or at opposite vertical ends of the section formwork.

6. The elongated member of claim 5, wherein the sheet member formwork is reused as the section formwork, and the height of each intermediate segment is equal to or less than the total height of the respective upper sheet member and lower sheet member.

7. An elongated member as described in claim 1, wherein the sheet members of each pair of sheet members have corresponding match cast surfaces formed at the cast interface between them.

8. An elongated member as described in claim 7, wherein each section has an outward-facing match cast surface that defines the opposite end of the section.

9. A wind tower comprising a long member as described in claim 1.

10. A method of assembling an elongated member for a wind tower, said elongated member having a plurality of sequentially arranged sections abutting longitudinally of said elongated member, said method comprising: a) forming a plurality of sheet member pairs, each including a lower sheet member and an upper sheet member, by casting the upper sheet member of each said sheet member pair onto its lower sheet member by introducing a hardenable material into a sheet member form, so that corresponding matched cast surfaces of the upper and lower sheet members of each sheet member pair are formed at the interface therebetween; b. separating the upper sheet member from the lower sheet member of each pair of sheet members; c) for each section form, placing a plurality of section forms and placing the top sheet member of a pair of sheet members on its bottom and the bottom sheet member of a subsequent pair of sheet members on its top; d) forming a plurality of sequential sections by casting an intermediate segment between the lower and upper sheet members of each of the section forms and introducing a hardenable material therein; e. arranging the sequentially ordered sections in a sequence such that the corresponding match cast surfaces of each pair of sheet members cooperatively seat in abutting contact to define the elongate member.

11. The method of claim 10 further comprising the step of casting the bottom sheet member of each of the plurality of sheet member pairs by introducing the curable material into the sheet member form.

12. 12. The method of claim 10 or 11, further comprising the step of casting the lower sheet member of each of the plurality of sheet member pairs by introducing a hardenable material into the sheet member form immediately prior to step (a).

13. 12. The method according to claim 10 or 11, wherein the sheet member formwork is reused as the section formwork, and the height of each segment is equal to or less than the total height of the respective upper and lower sheet members.

14. 1. A method of constructing an elongated member for a wind tower from a plurality of abutting sections, comprising: forming a first sheet member by casting the curable material against the second sheet member to define a corresponding plurality of match cast surfaces of the first sheet member and the second sheet member at an interface between the first sheet member and the second sheet member; b) forming a first one of the sections by casting a first section segment against the first sheet member using a curable material, whereby the first section segment projects longitudinally away from the first sheet member and the match-cast surface of the first sheet member appears at a bottom end of the first section; c) forming a second one of the sections by casting a second section segment against the second sheet member using a hardenable material, whereby the second section segment projects longitudinally away from the second sheet member, the match-cast surface of the second sheet member appearing at an upper end of the second section; and (d) stacking said first section on top of said second section such that said corresponding match-cast surfaces abut and cooperatively seat.

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