Offshore Foundation Pile Self-Leveling Concrete Filling
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Solution Overview
Problem
Existing methods for founding offshore structures with anchoring structures and foundation piles face challenges in achieving precise load transfer and height compensation due to geological inhomogeneities in the seabed, requiring complex spacer systems and difficult access for casting compounds after structure setup.
Innovation Solution
The method involves filling foundation piles with self-levelling, flowable concrete to a predetermined level before structure insertion, eliminating the need for spacers and allowing direct load transfer through the filling, which self-compacts and levels without vibration, and using wedges for pre-fixation and centering to prevent movement during hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are used to compensate for level differences in foundation piles, then height compensation is achieved, but device complexity increases
Solution Approach 1:
The invention removes the complex spacer system entirely and replaces it with a simple self-leveling concrete filling process. The concrete is poured into the foundation pile and automatically levels itself, eliminating the need for mechanical spacers and their associated complexity while achieving the same height compensation function.
Solution Approach 2:
The self-leveling concrete filling performs the height compensation function automatically through its own properties. The flowable concrete self-compacts and levels without external intervention or complex mechanical devices, making the system self-service and eliminating the need for spacers.
2Strength
If sleeves are attached to support legs for load transfer, then load transfer capability is improved, but device complexity increases
Solution Approach 1:
The invention eliminates the sleeves attached to support legs and replaces them with direct embedding of the support legs into the foundation pile through self-leveling concrete filling. This removes the intermediate sleeve component and its associated complexity while maintaining load transfer capability through the concrete bond.
Solution Approach 2:
The support leg and foundation pile connection is merged into a single integrated structure through the self-leveling concrete filling. The concrete fills the annular space between the support leg and foundation pile, creating a unified load transfer path that eliminates the need for separate sleeves.
3Productivity
If the structure is set down on foundation piles first, then load transfer begins, but access for casting compound becomes difficult
Solution Approach 1:
The invention performs the filling action before the structure is set down. The self-leveling concrete is poured into the foundation pile first, then the support legs are placed on top. This preliminary filling action ensures the annular space is accessible and properly filled before the structure is positioned, eliminating subsequent access difficulties.
Solution Approach 2:
The invention inverts the conventional sequence by filling the foundation pile with self-leveling concrete before setting down the structure, rather than attempting to inject casting compound after the structure is in place. This reversal of the process sequence makes the operation much easier and more effective.
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 simplifies the foundation process, ensures precise load transfer and height compensation, and facilitates easy introduction of casting compounds, enhancing stability and bonding between the structure and seabed.
Implementation Method 1
filling foundation piles with self-levelling, flowable concrete to a predetermined level before structure insertion, eliminating the need for spacers and allowing direct load transfer through the filling, which self-compacts and levels without vibration
Implementation Method 2
filling foundation piles with self-levelling, flowable concrete to a predetermined level before structure insertion, eliminating the need for spacers and allowing direct load transfer through the filling, which self-compacts and levels without vibration
Implementation Method 3
at least part of the structure being fixed within the foundation pile under load transfer into the seabed and being cast within the foundation pile using a hardenable mass
Data Source
Figure 1
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Figure 3~4
AI summary
The method involves fixing a part of an anchorage structure within a foundation pile (2) into a sea substrate (3) under load erosion. The part of the structure is cast within the foundation pile using a curable mass. The foundation pile is provided up to a predetermined level with a load-bearing, leveling filling (4) i.e. self compacting, flowable concrete, before the insertion of the structure. The structure is settled on the filling into the sea substrate and/or into the pile under the load erosion. Casting material (8) is introduced after settling of the structure on the filling. The part of the anchorage structure is a supporting leg. The foundation pile is designed as a steel tube. An independent claim is also included for a foundation for an off-shore building.