U.S. patent application number 14/102590 was filed with the patent office on 2014-04-10 for method for fabrication of structures used in construction of tower base supports.
This patent application is currently assigned to Tindall Corporation. The applicant listed for this patent is Tindall Corporation. Invention is credited to Kevin Lee Kirkley, Roger C. KNOX, Bryant Allan Zavitz.
Application Number | 20140097556 14/102590 |
Document ID | / |
Family ID | 41413477 |
Filed Date | 2014-04-10 |
United States Patent
Application |
20140097556 |
Kind Code |
A1 |
KNOX; Roger C. ; et
al. |
April 10, 2014 |
METHOD FOR FABRICATION OF STRUCTURES USED IN CONSTRUCTION OF TOWER
BASE SUPPORTS
Abstract
Disclosed are apparatus and corresponding methodologies for
providing a base support, such as including concrete, and used such
as for a wind-driven generator. Precast concrete cylinders are
stacked in place upon a platform that may be partially precast and
partially cast in place during assembly and supported, in certain
embodiments, by plural concrete legs, the other ends of which are
supported on a unitary or subdivided concrete foundation. In other
embodiments, the platform may be supported by ribbed concrete
panels. The concrete cylinders are glued together using an epoxy
and then secured by an internal vertical post tension system
extending from the platform to the upper most cylinder.
Methodologies and apparatus for fabrication of concrete structure
used in constructing the base support are also disclosed, with a
focus on staves and various ring piece constructions.
Inventors: |
KNOX; Roger C.;
(Spartanburg, SC) ; Zavitz; Bryant Allan;
(Dunwoody, GA) ; Kirkley; Kevin Lee; (Atlanta,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tindall Corporation |
Spartanburg |
SC |
US |
|
|
Assignee: |
Tindall Corporation
Spartanburg
SC
|
Family ID: |
41413477 |
Appl. No.: |
14/102590 |
Filed: |
December 11, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12482642 |
Jun 11, 2009 |
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14102590 |
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61174700 |
May 1, 2009 |
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61171965 |
Apr 23, 2009 |
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61143460 |
Jan 9, 2009 |
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61113354 |
Nov 11, 2008 |
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61061173 |
Jun 13, 2008 |
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Current U.S.
Class: |
264/327 |
Current CPC
Class: |
B28B 1/24 20130101; E04B
1/20 20130101; Y10S 416/06 20130101; Y02E 10/72 20130101; F05B
2240/9121 20130101; E04H 12/12 20130101; F03D 13/10 20160501; F03D
13/22 20160501; F05B 2240/913 20130101; E04H 12/342 20130101; E02D
27/425 20130101; Y02E 10/728 20130101; B28B 13/06 20130101; E04H
12/20 20130101 |
Class at
Publication: |
264/327 |
International
Class: |
B28B 13/06 20060101
B28B013/06; B28B 1/24 20060101 B28B001/24 |
Claims
1. A method of fabricating structures for use in construction of a
support tower, the method comprising: providing respective outer
diameter and inner diameter forms with the outer diameter form
situated adjacent to the inner diameter form so as to collectively
provide a concrete form defining a casting volume, the concrete
form having at least one inlet for injection of concrete into the
casting volume and at least one outlet for the displacement of air
therefrom; injecting concrete into the casting volume; curing the
concrete in the casting volume so as to form a casting; generating
a first thermal gradient between the casting and the outer diameter
form; removing the outer diameter form from the casting; generating
a second thermal gradient between the casting and the inner
diameter form; and removing the casting from the inner diameter
form.
2. The method of claim 1, wherein the generating the first thermal
gradient includes spraying steam onto the outer diameter form, or
using at least one heater embedded in the outer diameter form, or
combinations thereof.
3. The method of claim 1, wherein the generating a second thermal
gradient includes spraying water, air, or combinations thereof at
ambient temperature onto the inner diameter form.
4. The method of claim 1, wherein the removing the outer diameter
form includes lifting the outer diameter form.
5. The method of claim 1, wherein the removing the casting from the
inner diameter form includes pushing up on the casting, or lifting
the casting, or combinations thereof.
6. A method of fabricating a concrete casting comprising: providing
a first form and a second form with the first form situated
adjacent to the second form so as to collectively provide a
concrete form defining a casting volume, the concrete form having
at least one inlet for injection of concrete into the casting
volume and at least one outlet for the displacement of air
therefrom; injecting concrete into the casting volume; curing the
concrete in the casting volume so as to form the concrete casting;
generating a first thermal gradient between the concrete casting
and the first form; removing the first form from the concrete
casting; generating a second thermal gradient between the concrete
casting and the second form; and removing the concrete casting from
the second form.
7. The method of claim 6, wherein the first form and the second
form both have a curved shape.
8. The method of claim 7, wherein a radius of curvature of the
first form and a radius of curvature of the second form are
different.
9. The method of claim 6, wherein the generating the first thermal
gradient includes spraying steam onto the first form, or using at
least one heater embedded in the first form, or combinations
thereof.
10. The method of claim 6, wherein the generating a second thermal
gradient includes spraying water, air, or combinations thereof at
ambient temperature onto the second form.
11. The method of claim 6, wherein the removing the first form
includes lifting the first form.
12. The method of claim 6, wherein the removing the concrete
casting from the second form includes pushing up on the concrete
casting, or lifting the concrete casting, or combinations thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of previously filed U.S.
Provisional Patent Application entitled "CONCRETE BASE SUPPORT FOR
WIND-DRIVEN POWER GENERATORS," assigned U.S. Ser. No. 61/061,173,
filed Jun. 13, 2008; and claims the benefit of previously filed
U.S. Provisional Patent Application entitled "BASE SUPPORT FOR
WIND-DRIVEN POWER GENERATORS," assigned U.S. Ser. No. 61/113,354,
filed Nov. 11, 2008; and claims the benefit of previously filed
U.S. Provisional Patent Application entitled "BASE SUPPORT FOR
WIND-DRIVEN POWER GENERATORS," assigned U.S. Ser. No. 61/143,460,
filed Jan. 9, 2009; and claims the benefit of previously filed U.S.
Provisional Patent Application entitled "BASE SUPPORT FOR
WIND-DRIVEN POWER GENERATORS," assigned U.S. Ser. No. 61/171,965,
filed Apr. 23, 2009; and claims the benefit of previously filed
U.S. Provisional Patent Application entitled "METHOD AND APPARATUS
FOR FABRICATION OF STRUCTURES USED IN CONSTRUCTION OF TOWER BASE
SUPPORTS," assigned 61/174,700, filed May 1, 2009; and is a
divisional application of previously filed U.S. patent application
entitled "METHOD FOR FABRICATION OF STRUCTURES USED IN CONSTRUCTION
OF TOWER BASE SUPPORTS," assigned Ser. No. 12/482,642, filed Jun.
11, 2009; all of which are fully incorporated herein by reference
for all purposes.
FIELD OF THE INVENTION
[0002] The present subject matter relates to towers. More
specifically, the present subject matter relates to methodology and
apparatus for fabrication of staves and other components as may be
used in tower constructions, such as may be used in conjunction
with dynamic structures such as wind-driven power generators or
windmills or with other structures such as water towers.
BACKGROUND OF THE INVENTION
[0003] Construction of towers for support of various items has been
practiced for many years. Various towers of various materials have
been provided to support electrical transmission lines including
wooden, steel, and, more recently, concrete. In like manner, wind
driven apparatus including windmills and wind-driven power
generators in various forms and designed for many purposes,
including pumping of water from wells as well as, more recently,
generation of electrical power, have also been developed.
[0004] U.S. Pat. No. 3,793,794 to Archer et al. entitled "Stacked
Column" is directed to a column comprised of a plurality of
concrete-filled stacked tubes.
[0005] U.S. Pat. No. 4,406,094 to Hempel et al. entitled "Apparatus
for Anchoring Self-supporting, Tall Structures" is directed to an
anchoring self-supporting tall structure such as masts, towers, or
the like in a foundation. The mast or tower may be used to support
a wind-driven power generator.
[0006] U.S. Pat. No. 5,761,875 to Oliphant et al. entitled
"Reinforced concrete Pole with Attachment Mechanism" is directed to
an attachment mechanism which provides a structurally sound means
to attach a reinforced concrete pole to a support structure.
[0007] U.S. Pat. No. 6,532,700 to Maliszewski et al. entitled
"Flange With Cut For Wind Tower" is directed to a flange for making
a tower for a wind generator made up of a plurality of cylindrical
steel segments.
[0008] U.S. Pat. No. 7,155,875 to Henderson entitled "Method of
Forming a Perimeter Weighted Foundation For Wind Turbines And The
Like" is directed to a weighted foundation having a central pier
pedestal and an enlarged base space outwardly and extending below
the pedestal.
[0009] U.S. Pat. No. 5,586,417 to Henderson, et al. entitled
"Tensionless pier foundation" is directed to a hollow, cylindrical
pier foundation is constructed of cementitious material poured in
situ between inner and outer cylindrical corrugated metal pipe
shells.
The disclosures of all the patents referenced herein are
incorporated by reference, for all purposes.
[0010] In an article entitled "Precast concrete elements for wind
power industry," German company Enercon GmbH has described
methodology for casting concrete. Mexican company Postensa Wind
Structures describes on its website www.postensaws.com a tilt up,
precast on-site construction system for concrete towers for use
with wind driven power generators.
[0011] While various implementations of tower constructions have
been developed, and while various combinations of materials have
been employed for tower construction, no design has emerged that
generally encompasses all of the desired characteristics as
hereafter presented in accordance with the subject technology.
SUMMARY OF THE INVENTION
[0012] In view of the recognized features encountered in the prior
art and addressed by the present subject matter, improved apparatus
and methodology are presently disclosed for providing base supports
for windmills and wind-driven power generators (e.g., wind
turbines). It should be appreciated that while the present
disclosure is directed in exemplary fashion to support structure
involving precast concrete, various presently disclosed
constructions may be alternatively practiced in accordance with the
present subject matter.
[0013] In addition, it should be appreciated that while the present
disclosure is directed in exemplary fashion to support structure
for windmills and similar devices, such is not necessarily a
specific limitation of the present subject matter. For example, it
should be clear to those of ordinary skill in the art that a tower
constructed in accordance with the present technology may well be
used to support, for example, a television transmitter aerial or
other radio signal broadcasting aerial. Alternatively, towers
constructed in accordance with present technology may be used to
support any type device that may require placement above local
ground level for more effective operation. Such other present uses
may include, for example, such as electrical power transmission
lines and athletic field lighting equipment.
[0014] In one exemplary configuration, support for windmills may be
provided by stacking on-site a plurality of precast concrete
cylinders to form a self-supporting tower.
[0015] In one of its simpler forms, a first number of the precast
concrete cylinders may be provided as reinforced prestressed
concrete while a second number of the precast concrete cylinders
may be provided as ultra high performance fiber reinforced
concrete.
[0016] In accordance with aspects of certain embodiments of the
present subject matter, methodologies are provided to secure
individual precast concrete cylinders together using adhesives.
[0017] In accordance with certain aspects of other embodiments of
the present subject matter, methodologies have been developed to
provide a temporary support for a raised platform.
[0018] In accordance with yet additional aspects of further
embodiments of the present subject matter, apparatus and
accompanying methodologies have been developed to provide an
internal vertical post tensioning system within the stacked
concrete cylinders to maintain structural integrity of the stacked
assembly.
[0019] In accordance with yet further embodiments of the present
subject matter, a ribbed concrete block structure may be provided
as an alternative support for a raised tower supporting
platform.
[0020] In yet still further alternative embodiments of the present
subject matter, a tower supporting platform may correspond in part
to a precast portion and a field poured portion.
[0021] In accordance with further embodiments of the present
subject matter, a poured-in-place concrete circular strip footing
may be provided requiring little or no excavation.
[0022] In accordance with aspects of certain exemplary embodiments,
a conical skirt may be provided to distribute the tower load to the
foundation.
[0023] In accordance with yet further aspects of certain exemplary
embodiments of the present subject matter the foundation could be
precast and cast monolithically with vertical stave elements.
[0024] In accordance with yet still further aspects of certain
exemplary embodiments, the foundation may be configured to add
additional dead load by means of external ballasts.
[0025] In accordance with yet still further aspects of certain
exemplary embodiments, improved methodology and apparatus for
fabricating concrete structures used in the formation of base
supports are provided.
[0026] One present exemplary method in accordance with the present
technology relates to a method for fabricating precast concrete
structures for use in the construction of a support tower, Such a
method may include providing a concrete form having a transverse
axis and a longitudinal axis, such concrete form defining a casting
cavity having at least one injection port and at least one
ventilation port; tilting such concrete form about such transverse
axis or such longitudinal axis or both such that a first area of
such casting cavity is relatively raised with respect to a second
area of such casting cavity; and injecting concrete into such
casting cavity through such at least one injection port.
[0027] In variations of the foregoing exemplary method, such
injecting step may comprise injecting concrete into such casting
cavity upwardly from the second area of such casting cavity to the
relatively raised first area thereof. Also, optionally, such
tilting step may include selectively tilting such concrete form
about both its transverse axis and its longitudinal axis. In some
instances, such tilting step may include tilting such concrete form
about 45.degree. about its transverse axis and about 10.degree.
about its longitudinal axis.
[0028] In other alternatives of the foregoing, such method may
further include providing such concrete form with a plurality of
anchors; and securing pre-stressing tendons to such plurality of
anchors prior to injecting concrete into such casting cavity. In
another alternative, such method may include in instances vibrating
such concrete form to assist injection of concrete into such
casting cavity; and curing such concrete in such casting cavity to
form a casting. Such exemplary method may also include optionally
curing such concrete in such casting cavity to form a casting; and
heating such casting cavity to assist curing of such concrete in
such casting cavity.
[0029] Other variations of such exemplary method may include
providing such injection port with a shut-off valve; and closing
such shut-off valve after concrete has been injected into such
injection port. Yet other present exemplary variations may relate
to providing such concrete form with a plurality of injection ports
disposed along such casting cavity; injecting concrete made with
self-consolidating concrete mix into a first injection port of such
plurality of injection ports; and injecting concrete made with
self-consolidating concrete mix into a second injection port of
such plurality of injection ports, with such second injection port
relatively raised with respect to such first injection port.
[0030] In some instances, such casting cavity may be shaped to form
one of a concrete stave with a top portion and with a lower portion
having a greater width than such top portion, or to form a concrete
tubular structure.
[0031] Another present exemplary methodology embodiment relates to
a method of fabricating structures for use in construction of a
support tower. Such an exemplary present method may include
providing respective outer diameter and inner diameter forms with
the outer diameter form situated over the inner diameter form so as
to collectively provide a concrete form defining a casting volume,
such concrete form having at least one inlet for injection of
concrete into such casting volume and at least one outlet for the
displacement of air therefrom; injecting concrete into such casting
volume; curing such concrete in such casting volume so as to form a
casting; generating a first thermal gradient between such casting
and such outer diameter form; removing such outer diameter form
from such casting; generating a second thermal gradient between
such casting and such inner diameter form; and removing such
casting from such inner diameter form.
[0032] In the foregoing exemplary method, optionally generating
such first thermal gradient may include spraying steam onto such
outer diameter form, or using at least one heater embedded in such
outer diameter form, or combinations thereof. Similarly, generating
such second thermal gradient may include spraying water or air or
combinations thereof at ambient temperature onto such inner
diameter form. Such step of removing such outer diameter form may
include lifting such outer diameter form. Such step of removing
such casting from such inner diameter form may include pushing up
on such casting, or lifting such casting or combinations
thereof.
[0033] Yet another present exemplary embodiment relates to a method
of fabricating concrete structures for use in the construction of a
support tower, such a method preferably comprising providing a
lower concrete form defining a transverse axis and a longitudinal
axis; providing an upper concrete form having a top surface and a
bottom surface; inverting such upper concrete form so that such
bottom surface of such upper concrete form is above such top
surface of such concrete form; placing structural members onto such
bottom surface of such upper concrete form; securing such upper
concrete form to such lower concrete form so as to collectively
construct a concrete form assembly defining an enclosed casting
cavity having at least one concrete injection port and at least one
ventilation port; tilting such concrete form assembly about such
transverse axis or such longitudinal axis or both such that a first
casting area of such casting cavity is raised with respect to a
second casting area of such casting cavity; injecting concrete into
such casting cavity through such at least one concrete injection
port thereof, upwardly from such second casting area of such
casting cavity to such first casting area thereof such casting
cavity; curing such concrete in such enclosed casting cavity to
form a casting; separating such upper concrete form from such lower
concrete form; and removing such casting.
[0034] In one exemplary variation of the foregoing, such tilting
step may include tilting such concrete form about 45.degree. about
such transverse axis and about 10.degree. about such longitudinal
axis. In another present exemplary variation, such method may
further include providing such concrete form with a plurality of
injection ports disposed along such casting cavity; injecting
concrete into a first injection port of such plurality of injection
ports; and injecting concrete into a second injection port of such
plurality of injection ports, with such second injection port
relatively raised with respect to such first injection port. In
still further variations, such casting cavity may be shaped to form
one of a concrete stave with a top portion and with a lower portion
having a greater width than such top portion, or to form a concrete
tubular structure.
[0035] It is to be understood by those of ordinary skill in the art
from the disclosure herewith that the present subject matter
equally relates to both methodology as well as apparatus subject
matter. For example, one present exemplary embodiment relates to a
concrete form, preferably comprising a lower concrete form; and an
upper concrete form secured to such lower form to define an
enclosed casting volume within such concrete form. In such
exemplary apparatus, preferably such lower and upper concrete forms
collectively further define in such casting volume at least one
concrete injection port and at least one ventilation port, and
provide such casting volume with a shape for forming therein a
concrete stave with a top portion and with a lower portion having a
greater width than such top portion.
[0036] In variations of the foregoing apparatus, such exemplary
concrete form may further include anchors for securing
pre-stressing tendons. Still further, in some variations, such
ventilation port may be configured to be closed off; and such
injection port may include a shut-off valve. In yet other
alternatives, such concrete form may further include a plurality of
injection ports disposed along such casting volume; an embedded
heater; and a vibrator. In some embodiments, such upper form and
such lower form each may include structural reinforcing members to
allow such concrete form to be transported by a crane. In some,
such concrete form may further include at least one attachment
mechanism for securing such concrete form to a crane.
[0037] In another present exemplary embodiment, an exemplary
concrete form may comprise an inner diameter form; and an outer
diameter form received over such inner diameter form to define a
casting volume within such concrete form. In such arrangement,
preferably per present subject matter such inner and outer diameter
forms collectively may further define in such casting volume at
least one injection port and at least one ventilation port, and
provide such casting volume with a shape for forming therein a
concrete tubular structure.
[0038] In some present variations of the foregoing, such concrete
form may further include anchors for securing pre-stressing
tendons. Alternatively, such ventilation port may be configured to
be closed off; and such injection port may include a shut-off
valve. In other variations; such concrete form may further include
a plurality of injection ports disposed along such casting volume;
an embedded heater; and a vibrator. Also, such outer diameter form
and such inner form may each include structural reinforcing members
to allow such concrete form to be transported by a crane. Such
concrete form may further include at least one attachment mechanism
for securing such concrete form to a crane; and such inner diameter
form may comprise at least one jacking port.
[0039] Additional objects and advantages of the present subject
matter are set forth in, or will be apparent to, those of ordinary
skill in the art from the detailed description herein. Also, it
should be further appreciated that modifications and variations to
the specifically illustrated, referred and discussed features,
elements, and steps hereof may be practiced in various embodiments
and uses of the present subject matter without departing from the
spirit and scope of the subject matter. Variations may include, but
are not limited to, substitution of equivalent means, features, or
steps for those illustrated, referenced, or discussed, and the
functional, operational, or positional reversal of various parts,
features, steps, or the like.
[0040] Still further, it is to be understood that different
embodiments, as well as different presently preferred embodiments,
of the present subject matter may include various combinations or
configurations of presently disclosed features, steps, or elements,
or their equivalents (including combinations of features, parts, or
steps or configurations thereof not expressly shown in the figures
or stated in the detailed description of such figures).
[0041] Additional embodiments of the present subject matter, not
necessarily expressed in the summarized section, may include and
incorporate various combinations of aspects of features,
components, or steps referenced in the summarized objects above,
and/or other features, components, or steps as otherwise discussed
in this application. Those of ordinary skill in the art will better
appreciate the features and aspects of such embodiments, and
others, upon review of the remainder of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] A full and enabling disclosure of the present subject
matter, including the best mode thereof, directed to one of
ordinary skill in the art, is set forth in the specification, which
makes reference to the appended figures, in which:
[0043] FIG. 1 illustrates an exemplary embodiment of a concrete
base support, such as for a windmill, in accordance with the
present technology, fully installed and supporting a representative
exemplary windmill;
[0044] FIG. 2 illustrates a portion of a lower section of the
concrete base support in accordance with a exemplary embodiment of
present subject matter, illustrating a temporary support tower, guy
wires, and circular concrete base support;
[0045] FIG. 3 is an enlarge perspective view of the top portion of
the temporary tower illustrated in FIG. 2 with a precast concrete
transition piece placed thereon;
[0046] FIG. 4 illustrates the placement of a first pair of staves
positioned in balanced relationship on opposite sides of the
transition piece;
[0047] FIG. 5 is a top view taken from line 16-16 of FIG. 4 showing
a completed skirted base structure;
[0048] FIG. 6 illustrates a top perspective view of the precast
transition piece with all stays in place and banded around with a
corrugated metal collar;
[0049] FIG. 7 illustrates a view similar to that of FIG. 6 but
including a sealing plate that forms a portion of a tower hydraulic
lifting mechanism;
[0050] FIG. 8 illustrates a view similar to that of FIG. 7 but
including a tower lifting plate;
[0051] FIG. 9 illustrates a view similar to that of FIG. 8 and
including illustration of a first precast concrete tower section
shown partially in phantom to better illustrate aspects of the
internal construction;
[0052] FIG. 10 illustrates coupling of ducts within the staves and
precast concrete tower section to provide passageways for securing
strands;
[0053] FIG. 11 illustrates sealing and circumferential clamping of
the joint between the first section of precast concrete tower
portion and the precast transition piece;
[0054] FIG. 12 illustrates, partially in phantom, the stacking of
additional precast concrete tower sections and the insertion into
the stacked concrete sections of a steel tower section;
[0055] FIG. 13 illustrates an exemplary tower in accordance with
present technology in a fully extended position and supporting a
wind generator;
[0056] FIG. 14 illustrates a completed tower construction
supporting a wind generator but omitting the normally accompanying
turbine blade assembly;
[0057] FIG. 15 is a cross section of a portion of a precast base
including ballast fill and stave anchoring features in accordance
with certain exemplary embodiments of the present technology;
[0058] FIG. 16 illustrates a cross section of an alternate
configuration of the precast base structure that is identical to
that of FIG. 15 except that the upstanding wall section has been
replaced with a separated corrugated metal structure in accordance
with certain other exemplary embodiments of the present
technology;
[0059] FIG. 17 illustrates preliminary construction of a
multi-stage tower base for use with larger capacity turbines and
higher towers;
[0060] FIG. 18 illustrates an exemplary implementation of "U"
shaped tendons to provide multiple joint crossing and enhanced
stave retention;
[0061] FIG. 19 illustrates a top plan view of an exemplary concrete
form used to cast staves for use in exemplary embodiments of the
present technology;
[0062] FIG. 20 illustrates a cross-sectional view of an exemplary
concrete form used to cast staves for use in exemplary embodiments
of the present technology, taken along section line 20-20' as shown
in present FIG. 19, with dotted line representation of the concrete
form being tiltable in accordance with present subject matter about
a longitudinal axis of the form;
[0063] FIG. 21 illustrates a side view of an exemplary concrete
form used to cast staves for use in exemplary embodiments of the
present technology, with representative tilting of the concrete
form relative to its longitudinal axis, in accordance with certain
aspects of the present subject matter;
[0064] FIG. 22 illustrates a side view of an exemplary concrete
form used to cast staves for use in exemplary embodiments of the
present technology, with such form illustrated while situated
substantially parallel with the floor;
[0065] FIG. 23 illustrates a side view of an exemplary concrete
form used to cast staves for use in exemplary embodiments of the
present technology, and illustrating such concrete form being
lifted in the air by a plurality of attachment mechanisms, all in
accordance with certain aspects of the present subject matter;
[0066] FIG. 24 illustrates a composite location key for subfigures,
FIGS. 24A through 24D, which collectively illustrate an exemplary
layout of a facility where concrete staves may be cast according to
exemplary methodology and apparatus of the present technology;
[0067] FIG. 25 illustrates a further exemplary concrete form in
accordance with the present subject matter, used to cast ring
structures for use in exemplary embodiments of the present
technology;
[0068] FIG. 26 illustrates another view of an exemplary concrete
form used to cast ring structures for use in exemplary embodiments
of the present technology; and
[0069] FIGS. 27A through 27C variously illustrate the bottom
surface of an exemplary inner diameter concrete form used to cast
ring structures for use in exemplary embodiments of the present
technology, specifically with FIGS. 27B and 27C illustrating,
respectively, enlarged plan and cross-section views of exemplary
jacking port features of the present technology otherwise
representatively illustrated in present FIG. 27A.
[0070] Repeat use of reference characters throughout the present
specification and appended drawings is intended to represent same
or analogous features, elements, or steps of the present subject
matter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0071] As discussed in the Summary of the Invention section, the
present subject matter is particularly concerned with apparatus and
corresponding methodology for providing base supports, such as
comprised at least in part of precast concrete, and such as for
windmills and wind-driven power generators, or other
apparatuses.
[0072] Selected combinations of aspects of the disclosed technology
correspond to a plurality of different embodiments of the present
subject matter. It should be noted that each of the exemplary
embodiments presented and discussed herein should not insinuate
limitations of the present subject matter. Features or steps
illustrated or described as part of one embodiment may be used in
combination with aspects of another embodiment to yield yet further
embodiments. Additionally, certain features may be interchanged
with similar devices or features not expressly mentioned which
perform the same or similar function.
[0073] Reference will now be made in detail to the presently
preferred embodiments of the subject concrete base support, shown
for example, in support of representative exemplary windmills. With
reference to the drawings, FIG. 1 illustrates an exemplary
embodiment of a concrete base support generally 100, such as for a
windmill, in accordance with the present technology, illustrated as
fully installed and supporting a representative generator generally
120 and accompanying turbine blade assembly generally 122. Those of
ordinary skill in the art will appreciate that particular internal
details regarding such generator 120 and turbine blade assembly 122
form no particular aspects of the present subject matter, wherefore
further additional detailed discussion of such devices is not
required for a complete understanding of the present subject
matter.
[0074] Concrete base support 100 corresponds to a number or
plurality of sections, all of which are made of concrete in various
forms, so as to provide particular capabilities as required for
desired support of generator 120 and turbine blade assembly
122.
[0075] As may be seen from FIG. 1, concrete base support 100
corresponds to a leg section comprising, in an exemplary
configuration, such as eight legs representatively illustrated by
leg 114. Various numbers of legs may be practiced in accordance
with the present subject matter. Each of such legs 114 rests on an
individual foundation block generally 116. Further, each such leg
generally 114 is preferably inserted into one of a corresponding
number of mating holes 117 in a platform 112. In an exemplary
configuration, platform 112 may be constructed of reinforced
concrete, may be circular in shape, may have a diameter of twenty
six feet and may be four feet thick. Each leg 114 may measure four
feet by four feet and have eight inch thick walls.
[0076] Portions 102, 104, 106, and 108 of concrete base support 100
preferably vary in size as illustrated in and represented by FIG.
1, and also preferably are constructed with varying concrete
compositions. Portion 102 of concrete base support 100 corresponds
to a number of stacked reinforced prestressed concrete cylinders
representatively illustrated as cylinders 132, 134, 146. Each
cylinder 132, 134, 136 may also include reinforcing bars (rebars),
for example, common steel bar, as is commonly used in reinforced
concrete. Further, it should be noted that while the present
description may speak of concrete cylinders, such description does
not necessarily mean that the outer and/or inner shape is circular.
In fact the concrete cylinders constructed in accordance with the
present technology may correspond to cylindrical, octagonal,
hexagonal, or any other outside and/or inside surface formation or
combinations thereof.
[0077] Each of the concrete cylinders 132, 134, 136 in section 102
of concrete base support generally 100 preferably is substantially
the same size and similarly constructed of reinforced prestressed
concrete. Each of such cylinders also is preferably constructed for
mating assembly such that the top of one cylinder is shaped to mate
with the bottom of the next, i.e., adjacent, cylinder. As the
cylinders 132, 134, 136 are stacked, each preferably is adhesively
secured together using, for example, an epoxy or grout. In an
exemplary configuration, twenty cylinders may be stacked together
to form section 102 of concrete base support 100 where each
cylinder 132, 134, 136 may be six feet tall thereby producing a
section 102 which is one hundred twenty feet tall.
[0078] Following assembly of section 102 of concrete base support
100, a transition ring or cylinder 104 is placed on the top
cylinder of portion 102. As may be seen from the representations of
present FIG. 1, such transition cylinder 104 preferably varies in
diameter from a diameter corresponding to the diameter of section
102 to a smaller diameter matching the diameter of the cylinders
forming section 106. In an exemplary configuration, transition
cylinder 104 may have a midpoint diameter of thirteen feet and have
an eighteen inch thick wall. Transition cylinder 104 as well as
each of the cylinders in portion 106 of concrete base support 100
representatively illustrated as cylinders 142, 144, 146 are formed
of ultra high performance fiber reinforced concrete. In an
exemplary configuration, the ultra high performance fiber
reinforced concrete may employ steel fiber as the fiber component
of the concrete. In other embodiments, other fibers comprise of
other materials, now known or later developed, may be utilized.
[0079] As previously referenced, each cylinder of section 106,
representatively illustrated as cylinders 142, 144, 146, of
concrete base support generally 100 is constructed from ultra high
performance fiber reinforced concrete and may employ steel fiber
for reinforcement. In an exemplary configuration, seven cylinders
each fifteen feet tall may be stacked to produce a section 106
which is one hundred five feet tall.
[0080] Following assembly of section 106 of concrete base support
100, an additional cylinder 108 preferably is affixed to the top
most cylinder of portion 106. Top most cylinder 108 has a bottom
portion configured to mate with the top cylinder of portion 106 and
a top surface that provides a mounting surface for representative
generator 120. In addition, there is provided an anchoring ring to
secure one end of a post tensioning cable assembly that extends per
the present subject matter from such anchoring ring to a
corresponding anchor at platform 112.
[0081] Once each of the various cylinders have been stacked and
respectively glued into place, a cable 110 is passed through the
hollow center of each of the stacked cylinders, secured at the
anchor ring at the top of the string and at the anchor associated
with platform 112 (i.e., at the bottom of the string) and
tightened, thereby providing an internal vertical post tensioning
system to assist in securing each of the respective cylinders.
[0082] With reference now to FIGS. 2-19, an exemplary embodiment of
the present base support for wind-driven power generators will be
described. As may be seen in FIG. 2, a concrete base support and
temporary tower construction may be seen that is similar, in many
respects, to the previously described embodiment. As illustrated in
FIG. 2, there is provided a concrete base 216 including embedded
therein a number of anchor elements 218. Concrete base 216 may be
poured in place and requires minimal or nor excavation. In an
exemplary configuration, concrete base 216 may be sixty feet in
diameter and may be provided as a shallow foundation extending just
below the frost line, perhaps two to three feet in depth.
[0083] A second concrete base support 230 may be rectangular and
centrally positioned within an open space within the circular
concrete base 216. Concrete base support 230 is large enough to
provide support for temporary tower 210 which may be held in
position by one or more guy wires 224, 226. It should be
appreciated that while the present construction permits removal of
tower 210, such tower may, nevertheless, be retained for other
purposes including providing support for conductive cables
associated with the wind generator, for access to the central
portion of the rower above transition piece 312 or for other
purposes not directly related to the tower construction.
[0084] Referring now to FIG. 3, there is seen an enlarge
perspective view of the top portion of temporary tower 310
illustrated in FIG. 2 with a precast concrete transition piece 312
placed thereon. Transition piece 312 may be raised into position
using a crane or other suitable mechanisms and is placed on flat
pads 320, 322, 324 secured to the tops of vertical sections of
tower 310. Transition piece 312 simple sits in place in is more
securely positioned by placement of staves and other securing
devices as will be explained more fully later.
[0085] Transition piece 312 is constructed with as a multifaceted
precast concrete construction to include a number of facets 332,
334, 336, where the number of facets is equal to the number of
staves to be positioned about the perimeter of the transition piece
312. It should further be noticed that an elliptical aperture 340
is provided through the central portion of transition piece 312 and
provides a passage way through transition piece 312. Elliptical
aperture 340 provides for the removal of an elongated sealing plate
as will be more fully described later.
[0086] With reference now to FIGS. 4 and 5, it will be seen that a
number of pairs of staves 420, 422 are positioned with a wider base
portion 440 resting on concrete base 416 and a narrower top portion
432 simply leaning against a correspondingly sized facet 436 of
transition piece 412. Methods and apparatus for the manufacture of
staves 420, 422 will be discussed in detail below with reference to
FIGS. 19-23. Base portion 440 may be secure against radial and
lateral movement by attachment to one or more anchor elements 418.
FIG. 5 illustrates a top view taken from line 16-16 of FIG. 4
showing a completed skirted base structure including concrete base
516, plural pairs of staves 520, 522 positioned at top portions
thereof in contact with facets of transition piece 512. Also
illustrated is elliptical aperture 540 exposing portions of
temporary tower 510.
[0087] FIG. 6 illustrates a top perspective view of the precast
transition piece 612 with all staves 620, 622 in place and banded
around with a corrugated metal collar 652. Elliptical aperture 640
is also illustrated providing a passageway through transition piece
612. A number of additional features of transition piece 612 are
more clearly illustrated in FIG. 6 including a number of conduits
662, 664, 666, 668, the ends of which may be seen exposed on the
ends of staves 620, 622. Conduits 662, 664, 666, 668 extend, in
certain embodiments, through the length of staves 620, 622. In
certain other embodiments, conduits 662, 664, 666, 668 may extend
only a certain way down the length of staves 620, 622 to then turn
and join with other conduits to form a U-shaped conduit from the
top portion the individual stave to emerge as separate legs of the
U-shape in the same or, possibly adjacent stave. In assembled form,
the conduits provide a passage way for a metallic strand that may
be threaded through the conduits to provide strengthened assembly
of the various tower components. As will be explained further
later, the metallic strands may be extended through further
conduits provided in further tower portions to further assist in
securing the tower components together.
[0088] Referring to FIG. 7, it will be noticed that the
illustration is substantially identical to that of FIG. 6 with the
addition of a metallic plate 742 covering elliptical aperture 640
(FIG. 6). Metallic plate 742 may be constructed of steel and has
provided on the top portion thereof a number of standoffs 744, 746,
748 that are provided as support for a lifting plate to be
described later. It should be noticed that metallic plate 742 is
constructed to have a length and a width such that the width is
narrower than the longer length of the elliptical aperture 640 yet
the width is wider than the narrower width of the elliptical
aperture 640. In this way, metallic plate 742 may be turned so that
it will pass through elliptical aperture 640 for removal as an
optional final portion of the tower erection process.
[0089] FIG. 8 illustrates a view similar to that of FIG. 7 and
further illustrates a tower lifting plate 802. Positioned around
the perimeter of lifting plate 802 are a number of pedestals 804,
806, 808. Pedestals 804, 806, 808 generally correspond to portions
of an I-beam and include a flat top surface configured to interface
with end edge of a steel cylindrical tower portion and to lift the
steel cylindrical tower portion in place using air pressure as will
be described more fully later. In conjunction with the object of
lifting the steel cylindrical tower portion using air pressure, a
sealing ring 810 is provided around the outer perimeter of lifting
plate 802 that functions in combination with the inner surface of
one or more precast concrete tower sections to provide a
substantially air tight seal.
[0090] With reference to FIG. 9, there is illustrated a view
similar to that of FIG. 8 and further illustrating a first precast
concrete tower section 902 shown partially in phantom to better
illustrate aspects of the internal construction. As will be noticed
from FIG. 9, there are a number of conduits 904, 906, 908 provided
within the wall of the precast concrete tower section 902. Conduits
904, 906, 908 are positioned to cooperate with conduits 662, 664,
666, 668 incorporated into staves 620, 622 (FIG. 6) and provide
guides through which metallic threads may be passed to assist in
securing the various tower components together. As may be seen most
clearly in FIG. 9, precast concrete tower portion 902 is sized to
fit over lifting plate 802 and is supported in place by a number of
corbels or support blocks 822, 824 integrally incorporated into
transition piece 812 and radially extending from the perimeter
thereof, as best seen in FIG. 8.
[0091] With reference now to FIG. 10 there is illustrated a first
precast concrete tower section 1002 sitting in place on top of
transition piece 1012. Coupling ducts 1030, 1032, 1034, 1036, 1038
are installed to couple ducts within the staves 1020, 1022 and
precast concrete tower section 1002 to provide passageways for
securing metallic strands. Referring now to FIG. 11, it will be
seen that following placement of coupling ducts 1030, 1032, 1034,
1036, 1038, the space enclosed by corrugated metal band 1052 (FIG.
10) is filled with concrete 1102 and surrounded by a number of
circumferential clamps 1140, 1142, 1144, 1146 configured to place
the poured concrete filled corrugated metal band 1052 in
compression.
[0092] With reference now to FIG. 12, it will be seen that a number
of precast concrete cylindrical tower sections 1202, 1204, 1206 may
be stacked one upon another to extend the height of the tower. Each
section may include conduits as previously illustrated as conduits
904, 906, 908 in FIG. 9 and shown in phantom in tower section 1206
of FIG. 12. It should be appreciated that while three precast
concrete sections 1202, 1204, 1206 are illustrated in FIG. 12, such
number of sections is exemplary only. In practice the number of
sections may generally vary from one to four depending on desire
final height. It should also be noted that while the present
disclosure is directed primarily to the provision of precast
concrete tower sections, such is not a limitation of the present
subject matter in that these sections may be constructed of other
materials including steel.
[0093] After the desire number of precast concrete tower sections
have been stacked, a final cylindrical steel section 1208 is
positioned within the stacked concrete sections and lowered so as
to contact the plural pedestals 804, 806, 808 secured to the upper
surface of lifting plate 802 (FIG. 8). Cylindrical steel section
1208 includes a ringed tooth engagement mechanism (not separately
illustrated) on the lower portion of cylindrical steel section 1208
so that when cylindrical steel section 1208 is raised and later
rotated the mechanism meshes with a locking tooth mechanism
installed on the top portion of the top concrete tower section.
[0094] Referring now to FIG. 13, it will be seen that a wind
powered generator 1300 may be mounted to the top of cylindrical
steel section 1308 and the combination raised to a final operating
position by forcing compressed air into the space between the end
of the lower most precast concrete tower section 1306 and the
lifting plate 1302. Those of ordinary skill in the art will
appreciate that the normally required wind turbine blades
associated with wind generator 1300 may be attached to the
generator prior to raising the assembly. Such turbine blades are
not presently illustrated. FIG. 14 illustrates the assembled tower
in its fully extended position.
[0095] With reference now to FIG. 15 there is illustrated a cross
section of a portion of a precast concrete base 1516 including
ballast fill 1520, 1522 and stave anchoring features 1530 in
accordance with certain exemplary embodiments of the present
technology. As illustrated in FIG. 15, a feature of the present
subject matter resides in the ability of the base support to be
provided with minimal excavation requirements. As such, relatively
shallow foundations placed just below the frost line for the
particular tower location. Generally this will be two to three feet
deep. This feature of being able to provide a poured I place
circular strip footing as illustrated in FIG. 2 may be extended to
a precast concrete sectionalized base as illustrated in FIG. 15. As
shown in FIG. 15, base 1516 is provided with a flat lower portion
1540 and includes a radially outward outer upstanding wall 1542 and
includes integral formed stave portions 1542. Integral stave
portions 1542 include anchoring features 1530 corresponding to the
metallic strand receiving conduits previously discussed with
respect to FIG. 6 and conduits 662, 664, 666, 668. A plurality of
sections corresponding to base 1516 may be placed in a circular
trench containing compacted material 1550 which, in an exemplary
configuration, may be one to six feet thick. Each of the plurality
of sections may be secured together by metallic threads threaded
through integral conduits 1562, 1564 and the entire assembly may be
provided with additional ballast 1520, 1522 in the form of, for
example, a stone fill. FIG. 16 illustrates an alternate
configuration of the precast base structure that is identical in
every way to that of FIG. 15 except that upstanding wall section
1542 has been replaced with a separated corrugated metal structure
1642 and a series of post tensioning bands 1652 which function to
retain ballast.
[0096] Referring now to FIG. 17, there is illustrated a multi-stage
tower base generally 1700 designed to provide support, for example,
for larger capacity turbines positioned at heights higher than
single stage tower supports. As seen in FIG. 17, a top portion
generally 1702 of multi-stage tower base 1700 is constructed in a
manner similar to that shown and described in conjunction with
FIGS. 4 and 4. Thus, in FIG. 17 it will be seen that a number of
pairs of staves 1720, 1722 are positioned with a wider base portion
1740 resting on concrete base 1716 and a narrower top portion 1742
simply leaning against a correspondingly sized facet 1736 of
transition piece 1712.
[0097] In a manner similar to that illustrated in FIG. 5, a
completed top portion 1702 of skirted tower base 1700 includes
concrete base 1716 and plural pairs of staves similar to staves
1720, 1722 positioned with top portions thereof in contact with
other facets of transition piece 3712 and bottom portions resting
on concrete base 1716. In exemplary configurations, concrete base
portion 1716 may be either pre-cast or cast in place.
[0098] A lower portion generally 1704 of multi-stage tower base
1700 is similar to the top portion 1702 and supports concrete base
1716 by way of plural pairs of staves exemplarily illustrated as
staves 1744, 1746. A central supporting tower 1710 rests on
concrete support 1752 and extends from concrete support 1752,
through a central opening 1718 in concrete base 1716, and upward to
support transition piece 1712. As in previous embodiments, central
tower 1710 may correspond to a temporary or permanent
structure.
[0099] In an exemplary embodiment, the upper portion 1702 of tower
base 1700 may incorporate about six pairs or twelve staves while
lower portion 1704 may incorporate nine or ten pairs or eighteen to
twenty staves. Of course, different numbers of staves may be
incorporated in both the upper and lower portions of tower base
1700 depending on construction requirements for a particular
embodiment, or depending on particular design criteria for given
customers.
[0100] With reference now to FIG. 18, there is illustrated an
exemplary implementation of "U" shaped tendons to provide multiple
joint crossing and enhanced stave retention. The illustrated tower
section corresponds to a number of staves 1822, 1824, 1826
configured to support a concrete ring generally 1828, which staves
are secured together at least in part by a number of individual
tendons 1810, 1812, 1814, 1816. The assembly is designed to support
a cylindrical steel tube section 3802 with the assistance of tube
support structure 1804. An upper portion of steel tube 1802 (not
shown) may be configured as well understood by those of ordinary
skill in the art to support a wind turbine.
[0101] Staves 1822, 1824, 1826 abut each other at joints 1832,
1834, and are held in place by tendons 1810, 1812, 1814, 1816. In
accordance with present technology, tendons 1810, 1812, 1814, 1816
are configured to pass through tubes cast into concrete ring 1828
and each of the staves 1810, 1812, 1814, 1816 as "U" shaped
formations crossing adjacent staves at multiple locations generally
designated along lines X, Y, and Z.
[0102] An exemplary tendon 1842 is secured at the top of concrete
ring 1828 and passes through tubes embedded in concrete ring 1828.
Such exemplary tendon 1842 then passes through similar tubes
embedded in stave 1822 until it reaches a point 1844 where the
tendon is divided into a first portion that loops around to point
1854 and exits at point 1852 again at the top of concrete ring
1828. A second portion of tendon 1842 continues on to point 1846
where it again is split, with one portion going to point 1856 and a
second portion going on to point 1848. The tendon portion advancing
to point 1848 passes through tubes embedded in both staves 1822 and
1824, and then joins up with the remaining portions, including
those that pass through tubes in both staves 1822 and 1824 between
points 1846 to 1856 and 1844 to 1854. Similar separating and
rejoining of the several other tendons occurs with all of the
individual staves.
[0103] In accordance with present technology, such separating of
the individual tendons into multiple portions provides for enhanced
coupling of the staves at multiple points along joints 1832, 1824.
It should be appreciated that while present discussion describes
tendons separating into three portions, each coupling adjacent
staves at three separate points, the present subject matter is not
so limited; therefore, the tendons may be separated into three,
four or five or more portions, each crossing at separate points to
secure plural staves.
[0104] Referring now to FIGS. 19-27, exemplary methodology and
apparatus for the manufacture of precast concrete structures used
in the construction of a base support will be described. In FIGS.
19-23, a concrete form may be seen that is used to cast concrete
precast staves, similar to staves 420 and 422 illustrated in FIG.
4. The concrete form is used to cast pre-stressed injection mold
concrete staves in a manner that replicates the accuracy,
precision, and finish of known match-casting techniques. Precast
concrete staves molded using the techniques and apparatus described
herein have minimized defects in the surfaces of the stave,
allowing for accurate matching with other structures used for
example to construct the subject base support, including other
staves or transition pieces of the base support, such as transition
piece 312 shown FIG. 3. In such manner, the various structural
components of the base support may be secured together using
adhesives as opposed to grouted joint techniques.
[0105] It should be noted that the present methodologies may be
practiced in conjunction with the fabrication of other concrete
pieces involving fabrication of structures where the advantages
obtained for the concrete pieces herein described are desired.
Therefore, the present methodologies are not intended as being
limited to production only of the concrete pieces herein disclosed
or otherwise referenced.
[0106] With reference now to FIG. 19, a top plan view of an
exemplary concrete form generally 1900 used to manufacture
pre-stressed injection mold concrete staves is illustrated. Arrows
1905 indicate locations for anchors for pre-stressing tendons
placed in the concrete stave during its formation. The concrete
form 1900 forms an almost completely enclosed cavity into which
concrete is pumped from concrete feed yoke 1910. Once the concrete
form 1900 has been filled with concrete, the casting cures and
hardens inside the cavity formed by the concrete form 1900 to form
a concrete stave. Concrete form 1900 may also include various
conduits 1907 or other structural components that are cast into the
stave. Methodology for casting such conduits or structural
components into the stave will be discussed in more detail with
reference to FIG. 24 and FIGS. 24A-24D.
[0107] As will be understood by those of ordinary skill in the art
without additional discussion, concrete feed yoke 1910 may be
connected at one end to a concrete supply source (not shown). The
concrete supply source may be configured to provide a supply of any
type or mix of concrete desired for injection into concrete form
1900. For example, such concrete supply source may provide a supply
of a self-consolidating concrete mix for injection into the
concrete form 1900. As illustrated in FIG. 19, concrete feed yoke
1910 may for example include a Y-joint generally 1915 to split the
flow of concrete to opposite ends of the concrete form 1900.
Concrete feed yoke 1910 injects concrete into the concrete form
1900 at any of a plurality of concrete injection ports 1912, 1914,
1916 and 1918 located in the concrete form 1900. The number of
ports may be varied as desired or needed, particularly to
accommodate different sized pieces being prepared per the present
methodology and/or to accommodate variations in characteristics of
the concrete being poured.
[0108] As indicated, the concrete feed yoke 1910 can be moved up
and/or down the concrete form 1900 to inject concrete into
different areas of the concrete form 1900. For example, once the
area of the concrete form 1900 corresponding to injection port 1912
has been filled, the concrete feed yoke 1910 may be moved "up" the
concrete form 1900 and attached to injection port 1914 to fill the
area of the concrete form 1900 associated with injection port 1914.
It should be understood that in the present context the direction
"up" preferably refers to that end or side of the piece being
poured which is relatively raised. Therefore, the ports, in certain
present embodiments, could be located in spaced placements "moving"
from side to side of the form 1900, rather than from end to end
thereof. It should also be understood that the different areas of
the concrete form are not separated by any physical separator or
divider, but rather combine together to form one continuous
concrete form for molding of a concrete piece, in this example, a
concrete stave.
[0109] Concrete form 1900 may also have ventilation ports 1975 to
allow for the escape of air when the concrete form 1900 is being
filled with concrete. Ventilation ports 1975 may be any type of
vent for allowing the escape of air, and may operate with or
without vacuum assistance. After the concreted form 1900 has been
filled with concrete, the ventilation port may be configured to be
closed-off to provide a completely enclosed environment for curing
of the concrete. In addition, using the teachings provided herein,
those of ordinary skill in the art should appreciate that the
number and location of ventilation ports 1975 may varied as desired
or needed without deviating from the scope or spirit of the present
technology.
[0110] With reference now to FIG. 20, a cross-sectional view of a
concrete form 2000 similar to the concrete form 1900 shown in FIG.
19 can be seen, with such cross-section taken along section line
20-20'' of such FIG. 19. As illustrated, concrete form generally
2000 includes two separable pieces, in this instance an upper form
2020 and a lower form 2030. Upper form 2020 and lower form 2030
combine together to form a substantially enclosed cavity into which
concrete is injected in order to form casting 2040. During the
concrete injection process, upper form 2020 and lower form 2030 are
preferably secured together. One present methodology for such
securement is to make use of a mechanical clamping mechanism
generally 2025 such as, for example, a pin joint or a bolt joint.
Importantly, upper form 2020 and lower form 2030 are adapted to
completely cover, with the exception of injection ports and
ventilation ports 2075, the casting 2040 in the concrete form
2000.
[0111] Upper form 2020 and lower form 2030 may include structural
reinforcing members so that the concrete form 2000 is
self-supporting. In addition, upper form 2020 and lower form 2030
may include thermal insulation materials and/or electric heaters
embedded in the bodies of the upper form 2020 and the lower form
2030, respectively.
[0112] Such thermal insulation materials and/or embedded electric
heaters are useful per present subject matter in assisting the
concrete to cure and harden more efficiently, and with less heat
loss into the ambient air. The thermal insulation materials and/or
embedded heaters also reduce the amount of Portland cement needed
in the concrete, which reduces the emissions. Therefore, the
present concrete pouring methodologies make more efficient use of
energy while also contributing less heat into the surrounding
environment, for two-fold improvement involving environmental and
energy concerns.
[0113] Referring still to FIG. 20, representative concrete feed
yoke 2010 injects concrete (as represented by the plurality of
unlabeled arrows) into concrete form 2000 through respective
cut-off valves 2060 provided in the concrete form 2000 at the
plurality of concrete injection ports 1912, 1914, 1916 and 1918.
The cut-off valve 2060 may be a part of the concrete form 2000
itself and may be adapted to provide a tight seal for the concrete
form 2000 when concrete is not being injected through the cut off
valve 2060. As will be understood by those of ordinary skill in the
art, valves 2060 must be adapted so that they can open and close
even after concrete has cured in the area adjacent the valve 2060.
It is to be understood that the present methodologies are intended
to encompass variations in the specific constructions of such
representative valves 2060, or even the placement thereof relative
to a given feed yoke construction.
[0114] As illustrated, concrete form 2000 may also include
vibrators generally 2070. Vibrators 2070 may be used (if necessary
for particular concrete mixes and due to other factors), to assist
concrete 2040 in filling the cavity formed by upper form 2020 and
lower form 2030. For instance, vibrators 2070 may be particularly
useful during troubleshooting scenarios when there is difficulty
getting concrete to adequately flow into the concrete form
2000.
[0115] In FIG. 20, representative concrete form 2000 rests on
supports 2052 and 2054 extending from floor or base 2050. The
concrete form 2000, as illustrated, is resting so that the bottom
surface 2032 of the lower form 2030 is substantially parallel with
the floor or base 2050. However, in particular embodiments, the
height of support 2054 (or of support 2052 and/or any other
necessary supports) may be adjusted so that concrete form 2000 is
tilted about a transverse axis at an angle .theta. so that the
bottom surface 2032 of lower form is aligned along dashed line
2032' of FIG. 20. The angle .theta. may be any angle in the range
from about 0.degree. when the bottom surface 2032 is substantially
parallel to the floor or base 2050 to about 90.degree. when the
bottom surface 2032 is substantially perpendicular to the floor or
base 2050. In certain instances, it may be desirable for such angle
to be greater than 90.degree., such as to provide desired
positioning of the form and/or workpiece for other processing
considerations. As will be discussed below, the tilting of the
concrete form 2000 allows for the manufacture of concrete staves
(or other pieces) with minimized defects in the surfaces of the
stave (or other workpieces).
[0116] Referring now to FIG. 21, a side view of a concrete form
generally 2100 similar to those shown in FIGS. 19 and 20 can be
seen. Concrete form 2100 includes upper form 2120 and lower form
2130 that substantially enclose casting 2140. Concrete form 2100 is
supported by supports 2152 and 2152, which may be positioned and
configured such that concrete form 2100 is tilted about the
longitudinal axis by an angle of .PHI.. In other embodiments, the
concrete form 2100 may be tilted by attaching a crane to the
concrete form and lifting one end of the concrete form 2100 so that
the concrete form is tiled about the longitudinal axis by an angle
of .PHI.. The angle .PHI. may be any angle in the range from about
0.degree. when the bottom surface of the lower form 2130 is
substantially parallel to the floor or base 2150 to about
90.degree. (or more) when the bottom surface of the lower form 2130
is substantially perpendicular to the floor or base 2150. The only
potential limit on the angle .PHI. is the maximum height H that can
be attained for the concrete form 2100. As illustrated, as .PHI.
increases from about 0.degree. to about 90.degree., the height H of
the concrete form 2100 increase. There may exist certain
limitations on the height H, such as ceiling height of a
manufacturing facility, that may coincidentally serve as limits on
the angle .PHI., particularly where stave pieces may be on the
order of 90 feet in length.
[0117] As illustrated in FIGS. 20 and 21, the concrete form of the
present technology may be tilted about a transverse axis, about a
longitudinal axis, or about both a transverse axis and a
longitudinal axis, all in accordance with the present subject
matter. By injecting concrete "upwardly" into the tilted concrete
form starting from the lowest elevation of the concrete form to the
highest elevation, defects in the surface of a casting molded in
the concrete form may be minimized.
[0118] For example, referring to FIG. 19, if the concrete form 1900
was tilted about a longitudinal axis as shown in FIG. 21 so that
the portion of the concrete form 1900 corresponding to injection
port 1918 was located above the portion of the concrete form
corresponding to injection port 1912, concrete may first be
injected at the bottom of concrete form 1900 in the area
corresponding to injection port 1912. Once the area corresponding
to injection port 1912 has been filled, the concrete feed yoke 1910
may be moved upward as indicated by the unlabeled arrows to
injection port 1914. Once the area corresponding to injection port
1914 is filled, the concrete feed yoke 1910 may be moved even
further upward as indicated by the arrows to injection port 1916.
Once the area corresponding to injection port 1916 is filled, the
concrete feed yoke 1910 may be moved still even further upward as
indicated by the arrows to injection port 1918.
[0119] Utilizing such present technique, air pockets may be
minimized in the resulting injected concrete, resulting in fewer
defects on a surface or surfaces of the casting. The defects may be
even further minimized by controlling the pumping rate of the
concrete into the concrete form. By varying the tilt angle of the
concrete form about the longitudinal and/or transverse axis, and by
varying the pump rate of the concrete from the concrete yoke, an
optimal surface can be attained. All such combinations of
variations are intended to be encompassed by the present subject
matter.
[0120] As shown in FIG. 22, once concrete has been injected into
the concrete form generally 2200 according to the methodology
discussed herein, the concrete form 2200 may be arranged
substantially parallel with floor or base 2250 for curing and
hardening of the casting 2240. As illustrated, the supports 2252
and 2254 extending from or received on floor 2250 are configured
such that the concrete form 2200 lies substantially parallel with
floor 2250. A concrete form 2200 may be moved from a tilted support
arrangement, such as those representatively shown in FIG. 20 and
FIG. 21, to the substantially flat support arrangement of FIG. 22
through the use of any appropriate transportation mechanism,
including cranes. The details of such lifting/transportation
mechanisms are well known to those of ordinary skill in the art and
form no particular portion of the present subject matter.
[0121] As shown in FIG. 23, concrete form generally 2300 includes
per the present subject matter two attachment mechanisms 2380 for
securing the concrete form to a crane or other device (not shown,
or discussed in detail) for lifting the concrete form 2300. As
discussed earlier, upper form 2320 and lower form 2330 may each
include structural reinforcement so that the concrete form 2300 may
be effectively and safely transported by crane or the like from one
area or location to another, such as in or about a production
facility.
[0122] With reference now to FIG. 24 and subfigures, FIGS. 24A-24D,
an exemplary layout of a facility where the present technology may
be utilized is illustrated. As shown, FIG. 24 splits the exemplary
layout of the facility into four quadrants. Quadrant "A" represents
substantially where the equipment and apparatus depicted in FIG.
24A are located. Quadrant "B" represents substantially where the
equipment and apparatus depicted in FIG. 24B are located. Quadrant
"C" represents substantially where the equipment and apparatus
depicted in FIG. 24C are located. Quadrant "D" represents
substantially where the equipment and apparatus depicted in FIG.
24D are located.
[0123] With reference now to FIG. 24A, concrete is injected into
concrete forms at casting table station generally 2410. As
illustrated, casting table station 2410 includes two casting
tables, casting table "A" and casting table "B". At casting table
station 2410, concrete is injected into concrete forms similar to
the manner discussed above with reference to FIGS. 19-21. Per
present subject matter, the concrete form may be tilted along its
longitudinal axis, its transverse axis, or both to minimize defects
in the surface or surfaces of the casting.
[0124] After the concrete form has been completely injected with
concrete at casting table station 2410, the concrete form may be
moved, via crane as shown in FIG. 23 or by other form of
transportation, to curing station 2420. At curing station 2420, the
concrete form may be positioned substantially parallel with the
floor of the facility, similar to the concrete form 2200 shown in
FIG. 22. The concrete form remains at curing station 2420 until the
casting inside the concrete form has hardened and cured. A period
of eight hours is one example of approximate time in curing station
2420 which may be practiced in various present embodiments.
[0125] After the casting has cured inside the concrete form, the
concrete form may be transported to station 2430, which
transportation is represented in both FIG. 24A and FIG. 24B. At
station 2430, the upper form is removed from the concrete form and
the casting is removed. The casting may be removed, for example, by
a crane connected to chains threaded through conduits in the
casting (refer to exemplary conduits 1907 in present FIG. 19).
After the casting has been removed from the concrete form at
station 2430, the casting may be stored at station 2440 until it is
transported from the facility.
[0126] After the casting has been removed from concrete form, both
the upper form portion and the lower form of the concrete form may
be transported to fabrication shop 2450 shown in FIG. 23C for
repair, if necessary. In the alternative, the upper form and the
lower form may be transported to concrete form prep station 2460
shown in FIG. 24D.
[0127] At concrete form prep station 2460, both the lower form and
the upper form are cleaned and prepared for casting. During such
process, the upper form is inverted and held upside down. A crane
or other device may be used to invert the upper form. Once the
upper form is inverted, various structural reinforcing members and
conduits that are going to be cast into the concrete stave are
placed and secured in the upper form. After the various structural
reinforcing members and conduits have been placed in the inverted
upper form, the upper form and the lower form are transferred to
station 2470, where they wait to be used at casting table station
2410 shown in FIG. 24A.
[0128] Though not an aspect discussed in detail, each of FIGS. 24A
through 24D variously illustrate railed carts which may be used for
variously moving form and/or poured concrete pieces from station to
station. The railed carts may also be used to transport concrete or
other concrete pumping systems from station to station. Details of
such railed cart operations or similar are well understood by those
of ordinary skill in the art and form no particular aspect of the
present subject matter.
[0129] Referring now to FIGS. 25-27, a concrete form may be seen
that is used to cast concrete precast ring structures for use in
the base support. The concrete form is used to cast injection mold
concrete ring structures in a manner that replicates the accuracy,
precision, and finishes of known match-casting techniques. Precast
concrete ring structures molded using the techniques and apparatus
described herein have minimized defects in the surface or surfaces
of the ring structure, allowing for accurate matching with other
structures used to construct the base support, including other ring
structures or transition pieces of the base support, such as
transition piece 312 shown in FIG. 3. In such manner, the various
structural components of the base support may be secured together
using adhesives as opposed to grouted joint techniques.
[0130] With reference now to FIG. 25, an exemplary concrete form
generally 2500 used to manufacture injection mold concrete ring
structures is illustrated. The concrete form 2500 forms an almost
completely enclosed cavity into which concrete is pumped from
concrete feed yoke 2510 to form casting 2540. As illustrated,
concrete form 2500 includes an outer diameter form 2520 and an
inner diameter form 2530. Inner diameter form 2530 includes a
bottom surface 2532 upon which the bottom surface of the casting
2540 rests. Once the concrete form 2500 has been filled with
concrete, the casting 2540 cures and hardens inside the cavity
formed by the concrete form 2500 to form a concrete ring structure.
Concrete form 2500 may also include various conduits or other
structural components that are cast into the ring structure, the
details of which may vary in accordance with the particular
component or resulting structure under consideration.
[0131] Concrete feed yoke generally 2510 may be connected at one
end to a concrete supply source 2550. The concrete supply source
2550 (not shown) may be configured to provide a supply of any type
or mix of concrete as desired or as needed in a particular instance
for injection into concrete form 2500. For example, concrete supply
source may provide a supply of a self-consolidating concrete mix
for injection into the concrete form 2600. As illustrated in FIG.
25, concrete feed yoke 2510 may include a Y-joint to split the flow
of concrete to opposite sides of the concrete form 2500. Concrete
feed yoke 2510 injects concrete into the concrete form 2500 through
injection ports in the concrete form 2500. The concrete form 2500
may have a plurality of injection ports located throughout the
height of the concrete form 2500, similar to the plurality of
injection ports 1912, 1914, 1916, and 1918 discussed in conjunction
with present FIG. 19.
[0132] As illustrated, concrete feed yoke 2510 injects concrete
2540 into concrete form 2500 through cut-off valves 2560 provided
in the concrete form 2500 at the plurality of concrete injection
ports. The cut-off valve may be a part of the concrete form 2500
itself and may be adapted to provide a tight seal for the concrete
form 2500 when concrete is not being injected through the cut off
valve 2560. The valve 2560 should be adapted so that it can open
and close even after concrete has cured in the area adjacent the
valve 2560, as in the case with valves 2060 discussed above in
conjunction with present FIG. 20.
[0133] In accordance with the present subject matter and
methodologies, the concrete feed yoke 2510 may be adapted to inject
concrete into the concrete form 2500 from the lowest elevation of
the concrete form 2500 to the highest. For example, once the area
corresponding to the lowest injection port is filled, the concrete
feed yoke 2510 may be moved further upward to an injection port at
a higher elevation. By injecting concrete into the tilted concrete
form starting from the lowest elevation of the concrete form to the
highest elevation, defects in the surface of a casting molded in
the concrete form generally 2500 may be minimized in accordance
with the present subject matter.
[0134] Concrete form 2500 may also have ventilation ports 2575 to
allow for the escape of air when the concrete form 2500 is being
filled with concrete. Ventilation ports 2575 may be any type of
vent for allowing the escape of air, and may operate with or
without vacuum assistance. After the concreted form 2500 has been
filled with concrete, the ventilation port may be configured to be
closed-off to provide a completely enclosed environment for curing
of the concrete. In addition, using the teachings provided herein,
those of ordinary skill in the art should appreciate that the
number and location of ventilation ports 2575 may varied as desired
or needed without deviating from the scope or spirit of the present
technology.
[0135] Referring still to FIG. 25, it can be seen that similar to
the concrete form for casting staves described in FIGS. 19-13, the
concrete form generally 2500 may be tilted at a varying angle or
angles .theta. about a longitudinal and/or transverse axis such
that the bottom surface 2532 of the inner diameter form 2532 is
aligned along dashed line 2532' of FIG. 25. The angle .theta. be
any angle in the range from about 0.degree. to about 90.degree. (or
above in some circumstances).
[0136] Referring now to FIG. 26, the methodology and apparatus for
stripping the casting 2640 from concrete form 2600 will now be
discussed in detail. First, outer diameter form 2620 is removed
from the casting 2640 such as with the assistance of jacks pushing
up on jack supports 2610 and such as with cranes pulling up on
attachment elements 2680.
[0137] Due to the thermal expansion of the concrete form 2600
during the curing process of the casting 2640, it is helpful to
create a temperature gradient between the concrete form 2600 and
the casting 2640 to assist in removal of the outer diameter form
2620 from the casting 2640. In one embodiment, such temperature
gradient is created by spraying steam or other high temperature
water mixture generally 2692 onto the outer diameter form 2620. In
other embodiments, the thermal gradient may be created using
thermal insulation materials or embedded heaters in the outer
diameter form 2620. After the outer diameter form 2620 has been
sufficiently heated by the high temperature water mixture 2692, the
outer diameter form 2620 may be more easily removed from the
casting 2640.
[0138] After the outer diameter form 2620 has been removed from the
casting, the casting 2640 is removed from the inner diameter form
2630. The casting 2640 may be removed with the assistance of such
as cranes pulling up on the casting 2640 as well as with such as
jacks pushing up on the bottom surface 2632 of the inner diameter
form 2630 through jacking ports. Jacking ports are illustrated in
detail in FIG. 27A. FIG. 27A provides a plan view of the bottom
surface 2732 of an inner diameter form having a plurality of
jacking ports 2736. Further details of jacking ports 2736 are
provided in FIGS. 27B and 27C.
[0139] Similar to the outer diameter form 2620, it is helpful to
create a temperature gradient between the concrete form 2600 and
the casting 2640 to assist in removal of the inner diameter form
2630 from the casting 2640. In the case of the inner diameter form
2630, however, it is desirable to provide the opposite thermal
gradient to that provided between the outer diameter form 2620 and
the casting 2640. Accordingly, such temperature gradient is
preferably created by spraying an ambient temperature water
mixture, water vapor, or air, generally 2694, onto the inner
diameter form 2630. After the inner diameter form 2630 has been
sufficiently cooled by the ambient temperature water mixture 2694,
the inner diameter form 2630 may be more easily removed from the
casting 2640.
[0140] While the present subject matter has been described in
detail with respect to specific embodiments thereof, it will be
appreciated that those skilled in the art, upon attaining an
understanding of the foregoing, may readily produce alterations to,
variations of, and equivalents to such embodiments, both as to
present methodologies and apparatus. Accordingly, the scope of the
present disclosure is by way of example rather than by way of
limitation, and the subject disclosure does not preclude inclusion
of such modifications, variations, and/or additions to the present
subject matter (either concerning apparatus or methodology) as
would be readily apparent to one of ordinary skill in the art.
* * * * *
References