Slip-Formed Concrete Abrasion Resistance via Smooth Panels
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Solution Overview
Problem
Slip-formed concrete structures, particularly those exposed to harsh environments like ice-infested seas, suffer from irregular surfaces leading to reduced erosion and abrasion resistance, shorter service life, and higher maintenance costs due to inherent surface irregularities and lack of effective, affordable protection methods.
Innovation Solution
A method of forming a concrete structure with an increased abrasion allowance using concrete panels inside the slip form, eliminating steel armor reinforcement except for optional fibers, resulting in a smooth, plane, and hard surface, which is achieved by slip forming with panels that are later removed, ensuring a gradual transition and improved abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slip forming is used to form concrete structures, then the extent of work is greatly reduced and it is economical, but the surface includes irregularities such as small cracks, crazes or voids that reduce erosion and abrasion resistance
Solution Approach 1:
The patent applies preliminary action by using panels with smooth inner surfaces that are placed in the slip form before concrete pouring. These panels pre-establish the desired smooth surface geometry, and as the slip form is lifted, the panels are removed to leave the smooth surface intact, preventing irregularities from forming in the first place
Solution Approach 2:
The patent uses panels as intermediary elements between the slip form and the concrete structure. These panels temporarily serve as the forming surface, transferring the smooth surface geometry to the concrete, and are then removed after the concrete has set, leaving the smooth surface without the need for subsequent repair work
2Reliability
If steel protection structures are used to protect concrete structures from ice abrasion, then protection is provided, but the cost is very high requiring extensive scaffolding and additional work at high elevation
Solution Approach 1:
The patent changes the material parameter from steel to concrete for the protective layer. By using concrete panels with smooth inner surfaces during slip forming, the concrete structure itself achieves the smooth, abrasion-resistant surface that previously required expensive steel protection, thereby maintaining reliability while dramatically reducing manufacturing cost
Solution Approach 2:
The patent employs disposable concrete panels that are placed during slip forming and then removed. These panels serve their protective and forming function during construction, and their cost is minimal compared to permanent steel protection structures, making the overall solution economically advantageous
3Strength
If high strength, abrasion resistant concrete qualities are used, then abrasion resistance is improved, but surface irregularities are more pronounced leading to reduced service life
Solution Approach 1:
The patent applies preliminary action by using panels with smooth inner surfaces that are placed in the slip form before concrete pouring. These panels pre-establish the desired smooth surface geometry, and as the slip form is lifted, the panels are removed to leave the smooth surface intact, preventing irregularities from forming in the first place
Solution Approach 2:
The patent changes the surface quality parameter by introducing smooth panels as a controlling factor during concrete forming. This overrides the natural tendency of high-strength concrete to develop surface irregularities, achieving both high strength and smooth surface finish simultaneously
Data Source
Figure 1~5
AI summary
The invention provides a concrete structure of which at least a part has been formed by slip forming with panels inside the slip form, the panels facing the slip form.