Floating Caisson Construction via Sprayable Concrete Supports
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Solution Overview
Problem
The existing methods for constructing floating caissons are limited by the need for formworks, which restrict shape versatility, require expensive and tall construction docks, and result in inefficient use of resources, leading to delays in infrastructure projects.
Innovation Solution
A method and apparatus that spray concrete onto lightweight supports, allowing for the formation of walls with varied shapes without formworks, and enabling the construction process to occur at a consistent height, reducing the need for tall docks and increasing efficiency by lowering the platform after each wall portion is formed, using polystyrene foam supports and movable working decks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If formworks are used to construct caisson walls, then the construction process is structurally supported, but the shape versatility is limited to straight walls only
Solution Approach 1:
The invention extracts and removes the formwork element from the construction process entirely. Instead of using traditional formworks to mold concrete, the patent employs sprayable concrete that can be applied directly to supports, eliminating the formwork constraint and enabling curved and complex wall shapes without requiring complex formwork systems.
Solution Approach 2:
The invention changes the physical state and application method of concrete from poured/formwork-bound to sprayable. This parameter change in concrete delivery method allows the material to conform to any support shape, thereby achieving shape versatility while actually reducing device complexity since no complex formwork is needed.
2Length of stationary object
If tall construction docks are built to accommodate high caisson structures, then the full height of walls can be constructed, but the construction cost increases significantly
Solution Approach 1:
The invention segments the caisson wall construction into multiple manageable portions that can be constructed sequentially. By building walls in sections and joining them, the construction can proceed on smaller, more affordable docks rather than requiring single tall docks, thereby reducing construction dock costs while still achieving full wall height.
Solution Approach 2:
The invention introduces vertical dimensionality to the construction process by enabling multi-level working decks at different heights. This allows construction to progress upward through multiple levels on a single dock structure, eliminating the need for increasingly taller docks as the wall height increases, thus reducing dock construction costs.
3Ease of manufacture
If formworks are used for wall construction, then structural support is provided, but the construction process requires raising apparatus to higher levels, reducing efficiency
Solution Approach 1:
The invention inverts the traditional construction approach by keeping the working platforms at fixed, accessible levels and allowing the caisson structure to be built upward around them. Instead of raising workers and equipment to higher levels, the structure grows around stationary platforms, maintaining construction efficiency and eliminating the need for complex apparatus raising mechanisms.
4Strength
If conventional concrete construction methods are used, then structural strength is achieved, but the caisson weight increases, reducing buoyancy
Solution Approach 1:
The invention employs composite construction by combining sprayable concrete with reinforcement elements such as steel meshes or fibers. This composite approach achieves the required structural strength with potentially thinner wall sections, reducing overall caisson weight while maintaining strength requirements, thereby preserving buoyancy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for more versatile and cost-effective construction of floating caissons with improved strength and stiffness, reducing the need for expensive docks and enabling faster project completion by allowing curved and complex shapes, and enabling the caissons to be lighter while maintaining strength.
Implementation Method 1
a wall portion is formed by spraying or shooting concrete on the first and second outer faces of the supports
Implementation Method 2
The platform with already formed structure on top may be lowered by varying the buoyancy of the caisson and/or the platform
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~2A
AI summary
A method of forming a wall (121) of a floating caisson (100) is provided, which comprises: providing a slab (110) on a submersible platform (20); providing one or more base supports (130) on top of the slab (110), the base supports having a first outer face (132) and a second outer face (134); forming a first wall portion (121) by spraying concrete on the first and the second outer faces (132, 134); lowering the platform (20); and forming one or more subsequent wall portions on the first wall portion (121). Also disclosed are apparatuses (70) for constructing a floating caisson (100) and floating caissons (100).