Permanent formwork system for creating wall structures in tidal zones and underwater

Abstract

The invention relates to the field of building, and more particularly to formwork, and is a permanent beam-and-coupling formwork for casting reinforced concrete, including underwater and in tidal zones, and for producing concrete enclosing wall structures, including retaining walls, as well as shoreline-stabilizing hydraulic structures. The technical result of the claimed system lies in the possibility of constructing complex-shaped wall structures for built structures on shorelines (in tidal zones) and / or underwater, while providing for the strength and hardness of the entire structure, as well as the stability of the walls in an upright position. The claimed technical result is achieved by means of the design of a permanent formwork system for creating concrete enclosing wall structures underwater and in tidal zones, which includes a set of horizontally arranged tubes held together by elements of a frame, wherein some or all of the tubes of the set are connected to a manifold in the form of a length of tube having connector sleeves arranged at set intervals in a row for the connection of tubes of the set, and the frame consists of column tubes and coupling members, wherein the coupling members are in the form of hollow three-dimensional bodies with connector sleeves oriented at angles to one another, some of which are closed by plugs and the rest of which have tubes mounted therein.

Description

[0001] PERMANENT FORMWORK SYSTEM FOR CREATING WALL STRUCTURES IN THE TIDAL ZONE AND UNDERWATER

[0002] Field of technology.

[0003] The invention relates to the field of construction, namely to formwork, and is a permanent beam-node formwork for casting reinforced concrete, including underwater and in the tidal zone, the manufacture of wall enclosing structures from concrete, including retaining walls, as well as coastal protection hydraulic structures.

[0004] State of the art.

[0005] The prior art includes removable and permanent formwork for forming concrete structures of the "wall" type and various methods of joining such walls together (angle, tee, cross), made of steel, plywood, fiber concrete, foam plastics, glued-pressed sawdust, etc.

[0006] For example, a permanent formwork unit is known that includes formwork slabs connected to a spatial reinforcement lattice frame made of tubular elements, and lattice nodes are in the form of spherical elements connected to the formwork slabs, in which nests with internal threads are formed, and the tubes are equipped with tips located along their longitudinal axis with a threaded console protrusion for placement in the nests of spherical elements (RET 2029840 Cl, published 02 / 27 / 1995).

[0007] Also known is a permanent decorative formwork, which is spatially arranged flat elements, limiting at least part of the outer contour of the object being manufactured, wherein said flat elements are fastened together to form a space between these elements for placing reinforcement and filling with a flowable material capable of hardening, wherein said flat elements are made of thin sheet steel and are fragments of the outer contour of the object being manufactured, some of which are designed with the possibility of fastening with reinforcement to form part of the surface of the object being manufactured after hardening of the flowable material (RU 138426 U1, published 20.03.2014).

[0008] The above-mentioned types of formwork are of little use for casting concrete underwater due to the great difficulties with their assembly and disassembly in water or the rapid destruction of the formwork material in salt water. In addition, the known formwork is not suitable for casting concrete into wet (flooded) formwork and requires preliminary drainage of water from the casting mold - using cofferdams, caissons, temporary dams and other expensive methods. In addition, the known formwork is unsuitable for casting concrete under pressure from the bottom up and for forming complex volumetric structures, such as, for example, stepped retaining walls or zigzag structures "half-wall-half-wall".

[0009] Most of the known mass formwork systems for wall-type products are not designed to be moved in assembled form and require assembly from elements strictly on site. Such formwork systems, as a rule, are not suitable for assembly on the shore, with subsequent installation of a fully finished form for concrete in the water. The work of assembling the formwork under water is extremely expensive and dangerous. The overwhelming majority of such formwork cannot be easily removed from the concrete product that has gained strength under water, and they are abandoned under water, which causes significant environmental damage.

[0010] Disclosure of invention.

[0011] One of the technical problems solved by the proposed invention is the creation of a “wall” type fence, which is an optimal design in terms of strength-material consumption and strength-cost ratios for the underwater part of coastal protection hydraulic structures, such as malls, berth walls, embankments, dams, wet garages or transport infrastructure.

[0012] To solve the problem, unlike the known systems of permanent formwork that use wall panels, the proposed system uses a pack of horizontally laid pipes fixed in a frame (frames).

[0013] The technical result achieved by the patented system consists in the possibility of constructing wall structures of complex shape for coastal (in the tidal zone) and / or underwater structures, ensuring the strength and rigidity of the entire structure, as well as the stability of the walls in a vertical position.

[0014] The claimed technical result is achieved by means of a design of a permanent formwork system for creating enclosing wall structures made of concrete under water and in the tidal zone, including a pack of horizontally laid pipes held together by frame elements, wherein some of the pipes of the pack or all of the pipes of the pack are connected to a manifold, which is a section of pipe with branch pipes arranged in a row with a fixed pitch intended for connecting the pipes of the pack, and the frame consists of column pipes and nodal connecting elements, wherein the nodal connecting elements are made in the form of hollow volumetric bodies with branch pipes oriented at angles to each other, some of which are plugged, and pipes are installed in others.

[0015] In a particular case of implementing the invention, the frames can be assembled into a structure by connecting them together with beam pipes installed in the branch pipes of the nodal connecting elements. In a particular case of implementing the invention, the formwork includes external ties made of a metal or composite rod installed in the openings of the nodal connecting elements at an angle to the pipes.

[0016] In a particular case of implementing the invention, at least one branch pipe of the nodal connecting element is designed with the possibility of connecting a concrete pump to it for partial or complete filling of the formwork with concrete.

[0017] In a particular case of implementing the invention, the nodal connecting elements are made of polyethylene or PVC, or polypropylene, or metal, or fiberglass.

[0018] In a particular case of implementing the invention, standard water or gas or sewer pipes are used as pipes.

[0019] In a particular case of implementing the invention, the pipes are made of polyethylene or PVC, or polypropylene, or metal, or fiberglass.

[0020] In a particular case of implementing the invention, the pipes are secured in the branch pipes of the nodal connecting element by means of welding or a lock connection, or gluing, or a socket connection, or fixing with self-tapping screws, anchors, or rivets.

[0021] In a particular case of implementing the invention, at least one pipe of the pack is made with a window in its wall and passes through the manifold as a single whip, maintaining the possibility of filling it with concrete.

[0022] In a particular case of implementing the invention, the branch pipes of the nodal connecting elements are located coaxially with the possibility of through-placement of the frame pipes with or without a window. In a particular case of implementing the invention, the branch pipes of the nodal connecting elements are located coaxially with the possibility of through-placement of the rods.

[0023] In a particular case of the invention, the pipes are fixed in the manifold branch pipes by welding or a locking connection, or gluing, or a socket connection, or fixing with screws, anchors, or rivets. Or they pass through two coaxial manifold branch pipes.

[0024] In a particular case of implementing the invention, one of the manifold pipes is designed with the possibility of connecting to a concrete pump.

[0025] In a particular case of implementing the invention, the manifold contains 1-4 rows of nodes for connecting pipes from packs.

[0026] In a particular case of implementing the invention, part of the manifold pipes are plugged.

[0027] In a particular case of implementing the invention, the manifold is one of the frame columns.

[0028] In a particular case of implementing the invention, the manifold is made as a single unit with the nodal connecting element.

[0029] Description of drawings.

[0030] The solution is further explained with references to figures and three-dimensional models, which show the following:

[0031] Fig. 1 - general view of the frame.

[0032] Fig. 2 - general view of the manifold.

[0033] Fig. 3 - general view of the nodal connecting element.

[0034] Fig. 4 - general view of the formwork system. Fig. 5 - terraced embankment system.

[0035] Fig. 6 - Marine garage system.

[0036] Fig. 7 - G1 nodal connecting element for a wet garage.

[0037] Fig. 8 - nodal connecting element for the frame.

[0038] Fig. 9 and 10 are examples of manifolds for different tasks.

[0039] 3D model 1 - formwork system.

[0040] 3D model 2 - frame.

[0041] 3D model 3 - nodal connecting element.

[0042] 3D model 4 - manifold.

[0043] 3D model 5 - terraced embankment system.

[0044] 3D model 6 - marine garage system.

[0045] 3D model of 7-node G1 connector for marine garage.

[0046] 3D model of 8-node frame connector.

[0047] 3D models 9 and 10 are examples of manifolds for different tasks.

[0048] Implementation of the invention.

[0049] Permanent formwork systems for creating enclosing wall structures from concrete under water and in the tidal zone comprise a pack of 1 horizontally laid pipes held together by frame elements.

[0050] The frame consists of column pipes 2, nodal connecting elements 3 and beam pipes 4 in case of using frame structures. It is also possible to arrange frames with a given pitch without fastening them together. The nodal connecting elements are made in the form of hollow volumetric bodies with branch pipes 8 oriented at angles to each other, some of which are plugged, and beam pipes 4 and column pipes 2 are installed in others. Also, in a particular case of implementation, the formwork frame can include external rods 5 made of metal or composite rod installed in the openings of the nodal connecting elements at an angle to the column pipes and beam pipes. Column pipes 2 are used in assembling the frame and are standard plastic, composite or metal pipes.

[0051] Nodal connecting elements 3 allow to form a frame from pipe-beams and to fix the ends of the above-mentioned pipe-columns. The method of joining pipe-beams and pipe-columns to the nodal connecting element can be socket, coupling, adhesive, welded, flanged, threaded or other. The distance between the pipe-columns and their mutual arrangement allows to securely fix a straight or curved bundle of pipes in the frame described above.

[0052] The bundle of pipes is fixed with several separate frames assembled at a certain pitch or with a single frame structure containing several frames connected to each other by pipe beams - to give the entire structure greater strength and rigidity and to ensure the stability of the wall in a vertical working position.

[0053] The frame nodal connecting elements have a connector for connection to a concrete pipeline, which is a flange or groove lock or cam lock, for monolithic concreting of the frame.

[0054] In different cases of the invention implementation, joint concreting of frames and a bundle of pipes, as well as separate concreting, can be carried out. In the second case, the frame structure or individual frames, which have a relatively small internal volume of concreting, are first concreted, and after gaining strength, the bundle of pipes itself is concreted.

[0055] The nodal connecting element can have fastenings for several columns, creating two, three or more separate frames, which allows creating corners, tees or crosses in enclosing wall structures. Corners, tees or crosses are obtained from bundles of pipes combined along a common edge or corner.

[0056] The branch pipes of the nodal connecting elements are initially made plugged, and for assembly, holes are drilled in the required branch pipes with a crown or milling cutter, which allows the nodal connecting element to be adapted to different positions in the frame structure or different types of pipe packs - according to the thickness of the pipes in the pack or the bending angle of the pack in the case of forming a wall enclosure of a complex shape.

[0057] Part of the pipes of the pack are connected to manifold 6, which is a section of pipe with nozzles 7 for connecting pipes of pack 1, located at the same pitch.

[0058] The manifold ensures the formation of a single internal volume of pipes, necessary for the simultaneous concreting of the entire pack, and can also muffle or join the ends of the pipe whips. In some particular cases of implementing the invention, the manifolds can be made as a single unit with the nodal connecting element.

[0059] The specified step of manifold branch placement ensures fastening of either all pipes in a bundle or with alternation, for example, through one. In the second case, part is fastened to the manifold on one side, and the other part - on the other side.

[0060] The pipes of the bundle can be connected to the manifold, and the manifold, in turn, to the concrete pipeline by welding or a locking connection, or gluing, or a socket connection, or fixing with self-tapping screws, anchors, or rivets.

[0061] The manifold may contain one, two, three or four rows of branch pipes for connecting pipes of a bundle, which allows to assemble corners (bends), tees or crosses from bundles of pipes. Branch pipes also allow to blind a bundle of pipes and are used in the extreme (end) manifold. Through (coaxial) branch pipes in the manifold allow to extend pipe whips.

[0062] The manifold can replace one of the pipe columns in the frame or be located outside the frame. Examples of manifolds for different tasks are shown in Fig. 2, 9 and 10, as well as in 3D models 9 and 10.

[0063] Examples of implementation of the invention.

[0064] Example 1.

[0065] "Sea wall" structures implemented using concrete fixing frames, manifolds and stacks of horizontal or vertical HDPE pipes (see Fig. 4, 3D model 1). The pipe stacks are held together with reinforcement and filled with concrete through the manifolds, or the pipes are combined into a sea wall. Thus, the structure consists of nodal connectors with frame fastenings, manifolds and standard HDPE pipes forming a stack, frame columns and truss beams.

[0066] For flexible packs, it is preferable to use pipes with a diameter of 75-90 mm and columns with a diameter of 125 mm. For straight (rigid) packs, it is preferable to use pipes with a diameter of 125 mm and columns with a diameter of 160 mm.

[0067] These wall structures are used primarily for terrace coastal protection, the creation of malls, breakwaters and piers from marine gabions, as well as wet boathouses.

[0068] The main advantages of the wall structure series are the low weight of the empty formwork; the possibility of assembling relatively large monolithic structures; the "transparency" of the walls for water - which is important for rapid leveling of the groundwater level. Example 2.

[0069] The DUNE U45 terraced embankment system is designed to strengthen embankments or natural banks with a slope of 45° - 35°. It is also intended for use in seawater. The DUNE system is configured with the ability to create both horizontal double frames (for vertical immersed piles with a diameter of 140 mm) and vertical double frames (for bundles of HDPE pipes of 125 mm). As well as orthogonal double frames for the formation of two composite grids at a distance of 400 mm from each other to form marine gabions. It can be used with a retaining wall pitch of 100% or 50% in height or with a mixed pitch, as well as with a frame aspect ratio of 1: 1 or 1: 2. It is possible to separately concreting the frame and pipe bundles (when using manifolds). Works with Ml 2 and M13 manifolds. Concreting is carried out through GL4.5" flanges.

[0070] Terraces can be straight (steps), zigzag or mixed.

[0071] The shape of the terraces allows to reduce the number of fittings, pipes or reduce the volume of moved rubble and pebbles by repeating the natural water edge. To implement an architectural concept or to adjust the shape of an artificial dune.

[0072] It is possible to create "gabion" tiers near retaining walls.

[0073] Example 3.

[0074] A special case of a terraced embankment. Creation of a beach pier with the help of the described formwork for the possibility of placing sun loungers (Fig. 5, 3D model 5) in the tidal zone, allowing vacationers to be located in the specified zone at different heights. Arches from pipe packs hold sand and sand steps are formed. In addition to the resort purpose, such a structure with arched structures from pipe packs creates a beautiful effect of waves in the form of fish scales, during high tide in the coastal zone, which also has a positive effect on the recreational properties of the structure obtained with the help of the described formwork.

[0075] Example 4.

[0076] Marine garage (see Fig. 6, 3D model 6). The described invention can be used in the construction of marine garages (single, double and collective), located at a distance from the water's edge or cut into a fortified bank or embankment.

[0077] The garage can be embedded, in which case the gate is installed flush with the reinforced bank. The garage can also be made semi-embedded, when part of the garage walls and the gate significantly protrude beyond the reinforced bank. The system consists of nodal connecting elements G1 (see Fig. 7, 3D model 7), triple T-manifolds M13 and straight manifolds M12 (see Fig. 3, 3D model 4). The system contains everything necessary to create the underwater part of the structures and the tidal zone.

[0078] A wet garage does not, by default, have a continuous "sealed" floor, since it will be covered to some extent during storms.

[0079] The above-water part and garage doors are designed, purchased and installed separately. The use of vertical columns and braces provided in the nodal connecting element G1 is optional.

Claims

CLAUSES OF THE INVENTION 1. A permanent formwork system for creating enclosing wall structures made of concrete underwater and in the tidal zone, comprising a frame in which a bundle of pipes is fixed, wherein the frame consists of columns and nodal connecting elements, the nodal connecting elements of the frame are made in the form of hollow volumetric bodies with nozzles oriented at angles to each other, some of which are plugged, and columns are installed in others, and the manifold is a section of pipe with nozzles located at the same pitch, to which part of the pipes of the bundle or all the pipes of the bundle are connected, wherein the manifold is made in one piece with one nodal element of the frame or one of the columns is made in the form of a manifold.

2. The system according to item 1, in which external rods made of metal or composite rods are installed in the openings of the nodal connecting elements at an angle to the columns and / or pipes of the pack.

3. The system according to claim 1, in which at least one branch pipe of the nodal connecting element is designed with the possibility of connecting a concrete pump to it for filling the formwork with concrete.

4. The system according to claim 1, in which the nodal connecting elements are made of polyethylene or PVC, or polypropylene, or metal, or fiberglass.

5. The system according to paragraph 1, in which standard water, gas, or sewer pipes are used as the pipes of the bundle, columns, and pipe beams.

6. The system according to paragraph 1, in which the tube bundles, columns and tube beams are made of polyethylene or PVC, or polypropylene, or metal, or fiberglass.

7. The system according to claim 1, in which the columns and tubular beams are secured in the nozzles of the nodal connecting element by welding or a locking connection, or gluing, or a socket connection, or fixing with self-tapping screws, anchors, or rivets.

8. The system according to claim 1, in which at least one of the tubes of the pack, columns and / or tube beams is made with a window in its wall.

9. The system according to item 2, in which the branch pipes of the nodal connecting elements are located coaxially with the possibility of through-placement of the rods.

10. The system according to claim 1, in which the tubes of the bundle are secured in the manifold nozzles by welding or a lock connection, or gluing, or a socket connection, or fixing with self-tapping screws, anchors, or rivets.

11. The system according to claim 1, in which one of the manifold branches is designed with the possibility of connection to the concrete pipeline by means of welding or a lock connection, or gluing, or a socket connection, or fixing with a clamp or with self-tapping screws, anchors, or rivets.

12. The system according to claim 1, wherein the manifold comprises 1-4 rows of nozzles for connecting the tubes of the pack.

13. The system according to claim 1, in which part of the manifold nozzles are plugged.

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