Recess Former Assembly for Cast-In Pipe Lifting Anchors
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Solution Overview
Problem
Current methods for lifting and handling concrete pipes are inefficient and prone to damage, as they require slings or holes that can lead to instability and corrosion, and the installation of lifting anchors is complicated by varying pipe wall thickness and reinforcement configurations, making them difficult to integrate into modern pipe manufacturing processes.
Innovation Solution
A recess former assembly that adjusts to the distance between the mould and reinforcement cage, allowing for the economical installation of lifting anchors without modifying existing moulds, featuring a frame with locating lugs, a removable recess former, and a non-rigid interconnection to ensure proper anchoring and alignment during the concrete casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sling is used to lift concrete pipes, then lifting can be achieved, but the pipe becomes unstable and difficult to handle especially for large heavy pipes
Solution Approach 1:
The recess and lifting anchor are cast into the pipe during the manufacturing process, so the lifting attachment is already in place and properly positioned on the centre of gravity before the pipe is ever handled. This eliminates the need for temporary slings and provides stable, reliable lifting from the outset.
Solution Approach 2:
The lifting anchor acts as an intermediary element that provides a secure attachment point within the pipe. Instead of using external slings that wrap around the pipe, the anchor is embedded in the concrete and provides a reliable interface for lifting equipment, ensuring stability during handling.
2Measurement precision
If a hole is cast in the pipe wall for lifting, then the hole can be reliably located on the centre of gravity, but the hole must be plugged after use and there is risk of corrosion
Solution Approach 1:
The lifting anchor is designed as a permanent, simple concrete element that remains in place after lifting. Instead of creating a hole that needs to be plugged and protected from corrosion, the anchor itself becomes the final lifting attachment point, eliminating the need for additional protective measures.
3Manufacturing precision
If a recess former is attached to the mould to create a lifting anchor recess, then the anchor can be properly positioned, but the varying pipe wall thickness and reinforcement configurations make integration difficult
Solution Approach 1:
The recess former assembly incorporates a spring-loaded mechanism that allows it to dynamically adjust to varying distances between the mould wall and reinforcement cage. The spring enables the former to move forward or backward to accommodate different pipe wall thicknesses and reinforcement configurations while maintaining precise anchor positioning.
Solution Approach 2:
The system allows the position of the recess former relative to the mould to change based on the specific pipe design parameters. The spring mechanism enables adjustment of the former's position to account for variations in wall thickness and reinforcement placement, ensuring consistent anchor positioning across different pipe types.
4Manufacturing precision
If the recess former is non-rigidly interconnected to allow movement towards the mould, then proper anchoring is achieved, but the assembly becomes more complex
Solution Approach 1:
The spring-loaded recess former is designed to automatically adjust and position itself during the casting process. The spring mechanism self-regulates to push the former against the reinforcement cage or mould wall as needed, eliminating the need for complex external positioning mechanisms or manual adjustment during casting.
Data Source
AI summary
A recess former assembly (200) for creating a recess surrounding a cast in situ lifting element (60) in a cast concrete pipe (1) having a cast outer surface, is disclosed. The assembly has a frame (180) having locating lugs (183) engageable with components (81) of a reinforcing cage (80) to be positioned within the mould (70). The engagement of the lugs with the reinforcing components locates the frame in a rest position spaced from the mould. A removable recess former (150) is releasably retained in the frame. A lifting element (60) is retained within the recess former and has an anchor portion (64) extending therefrom. A non-rigid interconnection (182, 182A, 190, 191) between the lugs and the frame biases the frame and recess former to be urged towards the mould into an operative casting position in which at least a portion of the recess former substantially abuts the mould.