U.S. patent application number 16/383199 was filed with the patent office on 2019-12-05 for wall element system and method and apparatus for constructing shoring walls.
This patent application is currently assigned to Southern Seawall Solutions Pty Limited. The applicant listed for this patent is Southern Seawall Solutions Pty Limited. Invention is credited to Anthony Molloy.
Application Number | 20190368153 16/383199 |
Document ID | / |
Family ID | 68694496 |
Filed Date | 2019-12-05 |
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United States Patent
Application |
20190368153 |
Kind Code |
A1 |
Molloy; Anthony |
December 5, 2019 |
Wall Element System and Method and Apparatus for Constructing
Shoring Walls
Abstract
A caisson or casing 107 for installing a sheet 102/103 into a
ground or underwater location, the caisson 107 having a shaped wall
107.1, which is open for a predetermined length and is adapted to
receive and connect to an excavation means 3 within the confines of
the caisson or casing 107. In at least one embodiment, the system
includes a drilling assembly 3 for insertion of a caisson or casing
1, the drilling assembly 3 having one or more expanding drill bits
4 which are adapted to be driven by a drilling or rotation motive
device 5, the expanding drill bits 4 being adapted to be arranged
with respect to the caisson or casing 1 in use, so as form a hole
or bore which substantially conforms to, or substantially overlaps
with, the shape of the caisson or casing 1.
Inventors: |
Molloy; Anthony; (Tahmoor,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Southern Seawall Solutions Pty Limited |
Taren Point |
|
AU |
|
|
Assignee: |
Southern Seawall Solutions Pty
Limited
Taren Point
AU
|
Family ID: |
68694496 |
Appl. No.: |
16/383199 |
Filed: |
April 12, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E02D 2300/0006 20130101;
E02D 29/0266 20130101; E02D 2600/20 20130101; E02D 2300/0026
20130101; E02D 2300/002 20130101; E02F 5/02 20130101; E21B 7/208
20130101 |
International
Class: |
E02D 29/02 20060101
E02D029/02; E02F 5/02 20060101 E02F005/02 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 23, 2018 |
AU |
2018202809 |
Dec 31, 2018 |
AU |
2018286620 |
Claims
1. A retaining wall element or element of a formwork system for a
ground or underwater location, the retaining wall element or
element of a formwork system having a shaped wall which is open for
a predetermined length, which is adapted to receive and connect to
an excavation means within the confines of the retaining wall
element or element of a formwork system.
2. A retaining wall element or element of a formwork system as
claimed in claim 1, wherein the shaped wall has its free sides each
having a clutch, and a connecting section which closes the
retaining wall element or element of a formwork system.
3. A retaining wall element or element of a formwork system as
claimed in claim 2, wherein the connection section has a wall
portion with a mating clutch to join with the clutches at the wall
sides of the retaining wall element or element of a formwork
system.
4. A retaining wall element or element of a formwork system as
claimed in claim 2, wherein the connection section is formed from
one or more wall portions having clutches on it or them or can also
include at least one element clutch or join formation which is
adapted to engage another retaining wall element or formwork
element previously inserted in the ground or underwater
location.
5. A retaining wall element or element of a formwork system as
claimed in claim 2, wherein the connection section is a sheet pile,
panel, open section retaining wall element or formwork element or
is formed and/or shaped as a sheet pile, panel, open section
retaining wall element or formwork element so as to function as a
sheet pile, panel, open section retaining wall element or formwork
element, which is adapted, in use, to be separable from the
retaining wall element or element of a formwork system.
6. A retaining wall element or element of a formwork system as
claimed in claim 2, wherein the connection section has at least one
clutch, which is adapted to connect to at least one clutch of the
retaining wall element or element of a formwork system.
7. A retaining wall element or element of a formwork system as
claimed in claim 6, wherein the connection section has at least one
element join formation or clutch which is adapted to engage a
previously inserted retaining wall element or element of a formwork
system or clutch thereof.
8. A retaining wall element or element of a formwork system as
claimed in claim 7, wherein the at least one element mating join
formation or clutch on the connection section, by being adapted to
engage an retaining wall element or element of a formwork system or
clutch on one of these previously inserted in the ground or
underwater location, is adapted to act as a guide to guide the
retaining wall element or element of a formwork system, and an
excavation means combined therewith, as excavation occurs.
9. A retaining wall element or element of a formwork system as
claimed in claim 7, wherein said at least one element mating join
formation or clutch on the connection section is at least two such
element mating join formations or clutches.
10. A retaining wall element or element of a formwork system for
use in controlling land erosion in contact with water which wall
element or element of a formwork system comprises: self-supporting
polymeric construction, each having a vertical longitudinal
interior channel disposed therein enclosed by at least three sides;
each of said elements having a pair of opposed faces to which are
connected one or more fastening means; each of said elements
connected by mating engagement of the at least one fastening means
on one first element with at least one fastening means on said at
least one second element, said fastening means being an engageable
clutch or J-shaped hook; characterized in that at least one of said
elements includes in or on at least one of a front wall and/or rear
wall, an elongated fastening means allowing said at least one
element to connect to the ends of a wall or walls of a casing or
caisson and/or a drilling element, which will be used to drill
and/or keep clear a volume in which said element or elements will
be installed in an underwater location.
11. A wall element as claimed in claim 10, wherein said fastening
means on said front and/or said rear wall is an externally arranged
engageable clutch or J-shaped hook.
12. A wall element as claimed in claim 11, wherein said fastening
means on said front and/or said rear wall is an internally arranged
engageable clutch or groove able to receive a J-shaped hook.
13. A wall element as claimed in claim 12 which further comprises
at least one end cap having a fastening means to attach to said
element.
14. A wall element as claimed in claim 10, wherein said element is
constructed by its wall formation shape and/or thickness to
function as a structural wall when it is in a hollow condition.
15. A wall element as claimed in claim 10, wherein said wall
element is initially hollow and when joined and assembled with like
or similar elements, is then used as an in-situ formwork and
subsequently filled with concrete, cement or grout, or filled with
gravel to form a finished structural wall construction.
16. An excavation means for use with an open section retaining wall
element or element of a formwork system installed via a caisson or
casing so as to excavate in front of the leading edge of a
retaining wall element or element of a formwork system, said
excavation means having a body to mount at least one excavation
tool so that the at least one excavation tool is spaced from a wall
of the retaining wall element or element of a formwork system, or
if multiple tools are present they are spaced from each other so
that the outside diameter of the at least one excavation of the
tools are spaced from each other, said excavation means also
including at least one reaming portion which is formed from a
section or length of cable.
17. An excavation means as claimed in claim 16, wherein said
excavation means includes a flushing passage which discharges in a
direction at approximately 90 degrees to the axis of rotation of
the excavation means.
18. An excavation means as claimed in claim 16, wherein said
excavation means includes a flushing fluid system or drilling fluid
system which operates to pump drilling fluid from said excavation
means or a portion there of, at a pressure of the order of 50 psi
to 500 psi.
19. An excavation means as claimed in claim 16, wherein said
excavation means includes a shaped body or shaped guides which
locate said excavation means to excavate relative to or along a
pre-determined axis, which axis is located at an off-centre
location relative to the footprint of retaining wall element or
element of a formwork system.
20. An excavation means as claimed in claim 19, wherein said
off-centre location provides the extremities of a locus or rotation
envelope or excavation which clears the clutches of a previously
installed retaining wall element or element of a formwork system,
and which locus or rotation envelope or excavation extends past the
forward or opposite side clutches of the retaining wall element or
element of a formwork system being installed.
21. An excavation means as claimed in claim 16, wherein said
excavation means includes a segmented construction allowing the
assembly to be increased or decreased in length to suit different
lengths of said caisson or casing or open section retaining wall
element or element of a formwork system being installed.
22. An excavation means as claimed in claim 16, wherein said
excavation means is one of: a jet grouting tool; a drilling tool; a
reaming tool; a drilling and reaming tool.
Description
I. FIELD OF THE INVENTION
[0001] The present invention relates to placement of pile or wall
elements to construct shoring walls in difficult ground or ground
conditions on land or under water.
II. BACKGROUND OF THE INVENTION
[0002] Shoring walls can be constructed using interconnected pile
elements of various types. The pile elements can be manufactured
from various materials such as steel, stainless steel, aluminium,
glass fibre reinforced plastic, other composite materials or
precast concrete. Sheet pile comes in a variety of sections with a
variety of clutches and is manufactured from various materials,
such as steel, stainless steel; aluminium; glass reinforced plastic
or polymer, glass fibre reinforced plastic, fibre reinforced
plastic or polymer.
[0003] Various methods are currently used to construct pile walls,
and these methods include pushing, vibrating and hammering pile
elements whether sheet or panel or modular wall element into the
ground. In hard ground, a mandrel or pre drilling may be required.
When using glass fibre reinforced plastic (GFRP) or composite sheet
or aluminium sheets this problem is exacerbated. When installing
painted metal sheet into hard ground or abrasive ground, by any of
the conventional means, such conventional means will damage the
integrity of the painted coating.
[0004] All of the methods mentioned in the preceding paragraph have
their limitations and costs. Noise and vibration can often the
major limiting factors.
[0005] Any reference herein to known prior art does not, unless the
contrary indication appears, constitute an admission that such
prior art is commonly known by those skilled in the art to which
the invention relates, at the priority date of this
application.
[0006] For the purpose of this specification and claims:
[0007] a: a pile element, when constructed from material other than
concrete will be referred to as "the sheet" or "a sheet" each
element constructed from concrete will be referred to as `the
panel" or a panel. Additionally a pile element or panel can be an
open section retaining wall element, having 3 or 4 sides, and be of
plastic or metal, modular or bespoke, which can also serve the
function of a formwork system, for example such as that sold under
the brand TRULINE SEAWALL.
[0008] b: the means of attachment of one sheet or panel to another
sheet or panel will be referred to as "the clutch" or "a
clutch";
[0009] c: an enclosing structure used to place the sheet or panel
or wall element will be referred to as "the caisson or casing" or
"a caisson or casing";
[0010] d: an excavation means or assembly is any means to excavate
an area and includes: rotary means such as drilling and/or reaming
systems which may be expanding and/or contracting in nature or
non-expanding; rotating mechanical lever based systems which may be
expanding; swinging arm reaming type systems; or non-rotary means
such as jet grouter piling systems which operate on a grout or
drilling fluid being pumped under high pressure to fluidize a rock
bed. These excavation means can be positioned inside or outside of
the caisson or casing or modular wall elements and will sometime be
referred to as "the tool" or "a tool"; and
[0011] e: if drilling and/or reaming means are contained in the
tool they will be referred to as "drill bits" or if expandable
drill bits are used as "expandable bits" or "reaming elements" or
"expandable reaming elements".
[0012] By the expression "substantially conforms to" is meant a
situation where the drilling and/or reaming whether expandable or
not, simply rotate wholly within the footprint of the caisson or
casing.
III. SUMMARY OF THE INVENTION
[0013] The present invention provides an insertable element, being
one of an open section retaining wall element or a formwork element
or a caisson or casing for installing a pile element, such as a
sheet or panel or a pile wall element or an open section retaining
wall element or a formwork element, into a ground or underwater
location, the caisson having a shaped wall which is open for a
predetermined length, which is adapted to receive and connect to an
excavation means within the confines of the caisson or casing.
[0014] The shaped wall can have its free sides each having a
clutch, and a connecting section which closes the insertable
element and/or the shaped wall.
[0015] The connection section can have a wall portion with a mating
clutch to join with the clutches at the wall sides of the shaped
wall or the insertable element.
[0016] The connection section can be formed from one or more wall
portions having clutches on it or them or can also include at least
one element clutch or join formation which is adapted to engage
another insertable element or sheet or panel or open section
retaining wall element or formwork element previously inserted in
the ground or underwater location.
[0017] The connection section can be a sheet pile, panel, open
section retaining wall element or formwork element or is formed
and/or shaped as a sheet pile, panel, open section retaining wall
element or formwork element so as to function as a sheet pile,
panel, open section retaining wall element or formwork element,
which is adapted, in use, to be separable from the shaped wall.
[0018] The connection section can have at least one clutch, which
is adapted to connect to at least one clutch of the shaped
wall.
[0019] The connection section can have at least one element join
formation or clutch which is adapted to engage a previously
inserted insertable element, or open section retaining wall element
or formwork or panel or sheet or clutch thereof.
[0020] The at least one element mating join formation or clutch on
the connection section, by being adapted to engage an insertable
element or open section retaining wall element or formwork element
or panel or sheet or clutch on a one of these previously inserted
in the ground or underwater location, can be adapted to act as a
guide to guide the insertable element, and an excavation means
combined therewith, as excavation occurs.
[0021] The at least one element mating join formation or clutch can
be adapted to be located outside an excavation footprint of an
excavation means combined with the insertable element.
[0022] A releasable locking mechanism can interconnect the
connection section and the shaped wall or the insertable
element.
[0023] The locking mechanism can include one of the following: a
pin passing through mating clutches on the shaped wall or
insertable element and the connections section which can be removed
when needed; one of the connection section or the shaped wall or
the insertable element includes a flange portion provided to
receive a removable pin; a bolt or a wedge or any other mechanical
attachment or binding mechanism can be used to lock them
together.
[0024] The insertable element when combined with an excavation
means can be adapted to allow the excavation means to provide an
excavation footprint which can overlap an excavation footprint
related to the insertable element or a sheet or panel or a pile
wall element or an open section retaining wall element or a
formwork element previously inserted in the ground or underwater
location.
[0025] After the insertable element has been positioned in the
ground or underwater location, the connection section can be
separable from the shaped wall or insertable element.
[0026] The shaped wall or insertable element can be adapted so that
a sheet or panel or a pile wall element or an open section
retaining wall element or a formwork element can be made to engage
the clutch or join formation of a previous sheet or panel or a pile
wall element or an open section retaining wall element or a
formwork element, and pushed or hammered or vibrated into
position.
[0027] The shaped wall or insertable element can be removeable from
the ground or the underwater location, after the sheet pile or
panel or open section retaining wall element or formwork element is
positioned, the insertable element being a caisson or casing.
[0028] The present invention also provides the insertable element
as described above in combination with an excavation means.
[0029] The excavation means can be a drilling and/or assembly
having one or more drilling bits and/or reaming elements which are
adapted to be driven by a drilling or rotation motive device, the
drilling bits and/or reaming elements can be adapted to be arranged
with respect to the insertable element in use, so as form a hole or
bore or excavation which substantially conforms to or substantially
overlaps with, the shape of the insertable element.
[0030] The one or more drilling bits and/or reaming elements can be
adapted to be positioned ahead of a leading edge of the insertable
element, or are positioned so as to excavate from within the
confines of the insertable element.
[0031] The drilling bits and/or reaming elements can be one of the
following: expanding drilling bits; non-expanding drill bits;
expanding reaming elements; non-expanding reaming elements.
[0032] The excavation means and/or caisson or casing can allow the
excavation means to be withdrawn from the caisson or casing.
[0033] The excavation means can have one or more of the following
features: when in an expanded condition, engages ground beyond part
or all of a leading edge of the insertable element; when in the
unexpanded or retracted condition remains inside the insertable
element opening or opening footprint; when the excavation means is
not an expanding excavation means, it remains inside the insertable
element opening or opening footprint.
[0034] The drilling bits and/or reaming elements can be rotated by
at least one motor located within the insertable element.
[0035] The drilling bits and/or reaming elements can be rotated by
at least one motor located outside the insertable element.
[0036] The drilling bits and/or reaming elements can be rotated by
other mechanical means whether individually or in unison.
[0037] The excavation means can be mounted for being pulled towards
or pushed away from the insertable element.
[0038] The excavation means can be provided with a means of
flushing by air, liquid, slurry, mud or a combination of any two or
more of these or all of these.
[0039] Part of the excavation means can be adapted to be positioned
ahead of a leading edge of the insertable element.
[0040] The excavation means can be adapted to be attached to the
insertable element.
[0041] The excavation means can be releasably attachable to the
insertable element.
[0042] The insertable element can be constructed from two or more
sections.
[0043] The excavation means can substantially close off an opening
formed by an inner periphery of the insertable element.
[0044] The excavation means can be one or more excavation means are
used for the opening.
[0045] The excavation means can excavates hard ground or drills
and/or reams hard ground, allowing the insertable element to be
positioned to a predetermined or required depth.
[0046] There can be a spacing or gap between an interior surface of
the insertable element and a body of the excavation means.
[0047] The spacing or gap can be of the order of 2 to 10
millimeters, or more preferably of the order of 2 mm to 5 mm.
[0048] The connection section can be unconnected to excavation
means to be associated with the insertable element.
[0049] The excavation means to be associated with the insertable
element, is connected to or is a releasable part of the shaped wall
or insertable element.
[0050] The present invention also provides a method of inserting an
insertable element being one of an open section retaining wall
element or a formwork element or a caisson or casing for installing
a pile element, such as a sheet or panel or a pile wall element or
an open section retaining wall element or a formwork, or a sheet
pile or panel or open section retaining wall element or a formwork
system or element of such a formwork system installed via a caisson
or casing, the method including: providing an insertable element or
a pile element, such as a sheet or panel or a pile wall element or
an open section retaining wall element or a formwork, providing an
excavation means which is expandable to excavate outside or within
the confines of the insertable element and withdrawable from the
confines of the insertable element; utilizing an earlier installed
insertable element or pile element as an excavation or drilling
and/or reaming guide or if the insertable element is open,
overlapping the excavation area of the new insertable element or
pile element with that of an earlier installed insertable element
or pile element.
[0051] The method can include use of a connection section to engage
the insertable element or the pile element.
[0052] The connection section can enable the insertable element or
the pile element to be guided by the earlier installed insertable
element or the pile element.
[0053] The connection section can also act as a sheet pile or panel
or open section retaining wall element or formwork element and
remains in the ground or underwater location.
[0054] The present invention also provides an excavation means for
use with an insertable element being one of an open section
retaining wall element or a formwork element or a caisson or casing
for installing a pile element, such as a sheet or panel or a pile
wall element or an open section retaining wall element or a
formwork, or a sheet pile or panel or open section retaining wall
element or a formwork system or element of such a formwork system
installed via a caisson or casing so as to excavate in front of the
leading edge of insertable element or the pile element, the
excavation means having a body to mount at least one excavation
tool so that the at least one excavation tool is spaced from a wall
of the insertable element or the pile element, or if multiple tools
are present they are spaced from each other so that the outside
diameter of the at least one excavation of the tools are spaced
from each other.
[0055] The excavation means can include a detachable connection to
an insertable element or the pile element with which it will be
used.
[0056] The excavation means can be one of a jet grouter; a drilling
tool; a reaming tool; a drilling and/or reaming tool; or drilling
and/or reaming tool assembly.
[0057] The excavation means can include expandable drilling and/or
reaming bits or portions.
[0058] The present invention also provides a method of excavation
for an insertable element being one of an open section retaining
wall element or a formwork element or a caisson or casing for
installing a pile element, such as a sheet or panel or a pile wall
element or an open section retaining wall element or a formwork, or
a sheet pile or panel or open section retaining wall element or a
formwork system or element of such a formwork system installed via
a caisson or casing, the method including the steps of: providing a
an insertable element or pile element; attaching to the insertable
element or a pile element an excavation means as described above;
advancing the excavation means to excavate ground beneath the
excavation means until the insertable element or pile element
engages hard ground or is otherwise at a sufficient depth;
detaching the excavation means from insertable element or pile
element excavating ahead of insertable element or pile element to a
predetermined depth; withdrawing the excavation means from
insertable element or pile element; repeating as many times as
needed to situate the insertable element or pile element until a
desired length of shoring wall is achieved.
[0059] The present invention also provides an excavation means and
an insertable element being one of an open section retaining wall
element or a formwork element or a caisson or casing for installing
a pile element, such as a sheet or panel or a pile wall element or
an open section retaining wall element or a formwork, for insertion
into ground, the excavation means being able to excavate inside the
opening or opening footprint of the insertable element, the
excavation means having a body to mount at least one excavation
tool so that overlapping excavations will result.
[0060] The excavation means can include a detachable connection to
the insertable element.
[0061] There can be at least one excavation tool, which in the case
of one tool is spaced from an end wall of the insertable element,
and in the case of more than one tool are spaced from each other so
that the outside diameter of excavation of the tools are spaced
from each other so that when the body is rotated through 180
degrees, the excavation that occurs produces an overlapped
excavation footprint, so as to provide a mirror reverse excavation
footprint.
[0062] The excavation means can be one of: a jet grouter; one or
more drilling tools; a drilling tool assembly; a drilling and/or
reaming tool; or a reaming tool.
[0063] The excavation means can includes: only expandable drilling
and/or reaming bits; or only non-expanding drill bits; or a
combination of expanding and non-expanding where the expanding
drill or reaming bits when expanded have the same or a greater
outside diameter as the non-expanding drill bits.
[0064] The present invention also provides a method of excavating
ground, either above or under water, for insertion of an insertable
element being one of an open section retaining wall element or a
formwork element or a caisson or casing for installing a pile
element, such as a sheet or panel or a pile wall element or an open
section retaining wall element or a formwork, the method including
the steps of: providing an insertable element and an excavation
means or assembly as described above; activating the excavation
means to excavate ground beneath the excavation means so as to
produce an excavation or a series of overlapped excavations outside
of or within the opening or opening footprint of the insertable
element.
[0065] The present invention further provides a drilling and/or
reaming assembly for insertion of an insertable element being one
of an open section retaining wall element or a formwork element or
a caisson or casing for installing a pile element, such as a sheet
or panel or a pile wall element or an open section retaining wall
element or a formwork, or a sheet pile or panel or open section
retaining wall element or a formwork system or element of such a
formwork system installed via a caisson or casing, the drilling
and/or reaming assembly having one or more drilling and/or reaming
bits which are adapted to be driven by a drilling or rotation
motive device, the drill and/or reaming bits being adapted to be
arranged with respect to the insertable element, so as form a hole
or bore into which can be inserted the insertable element.
[0066] The drilling and/or reaming bits can be adapted to be
positioned ahead of a leading edge of the insertable element.
[0067] The drilling and/or reaming bits can be expanding drilling
and/or reaming bits.
[0068] The expanding drill and/or reaming bits when in a retracted
condition, can allow the drilling and/or reaming assembly to be
inserted into and/or withdrawn from the insertable element.
[0069] The expanding drilling and/or reaming bits, when in an
expanded condition, can have ground engaging bits or portions
extending beyond part of a leading edge of the insertable
element.
[0070] The drilling and/or reaming bits can be rotated by a motor
located within the insertable element.
[0071] The drilling and/or reaming bits can be rotated by motor
means located outside the insertable element.
[0072] The drilling and/or reaming bits can be rotated by other
mechanical means whether individually or in unison.
[0073] The drilling and/or reaming assembly can be mounted for
being pulled towards or pushed away from the insertable
element.
[0074] The drilling and/or reaming assembly can be provided with a
means of flushing which has one or more of the following features:
flushing by air, liquid, slurry, mud or a combination of two or
more of these or all of these; is delivered at a pressure of the
order of 50 psi to 500 psi; exits the drilling and/or reaming
assembly in a horizontal direction from the drilling and/or reaming
assembly when it is vertical; exits the drilling and/or reaming
assembly at approximately 90 degrees to the longitudinal axis of
the drilling and/or reaming assembly.
[0075] The one or more drilling and/or reaming bits can be adapted
to be positioned ahead of a leading edge of the insertable
element.
[0076] The drilling and/or reaming assembly can be adapted to be
attached to the insertable element.
[0077] The drilling and/or reaming assembly can be releasably
attachable to the insertable element.
[0078] The insertable element does not rotate as it advances
downwardly.
[0079] The insertable element can have at least one first clutch on
one side so as to engage a mating shaped clutch on a previously
installed insertable element.
[0080] The insertable element can have one of the following: two
clutches on one side; or two clutches on one side and two clutches
on an opposite side.
[0081] The insertable element can be constructed from two or more
sections.
[0082] The insertable element can be such that the at least one
element mating join formation or clutch on the connection section
is at least two such element mating join formations or
clutches.
[0083] The connection section can have at least two element mating
join formation or clutches.
[0084] The drilling assembly can substantially close off an opening
formed by an inner periphery of the insertable element.
[0085] Multiple drilling and/or reaming bits or heads can be used
for each opening.
[0086] The drilling and/or reaming assembly can disturb,
plasticize, fluidize, or worry a bed drilled and/or reamed by the
drilling and/or reaming assembly, allowing the insertable element
to be positioned to a predetermined or required depth.
[0087] There can be a spacing or gap between an interior surface of
the insertable element and a body of the drilling and/or reaming
assembly.
[0088] The spacing or gap is of the order of 2 to 10 millimeters
but is most preferred to be of the order of 2 mm to 5 mm.
[0089] The excavation means can include at least one reaming
portion which is formed from a section or length of cable or spring
steel or an articulated ground engaging member.
[0090] The excavation means can include a flushing passage which
discharges in a direction at approximately 90 degrees to the
longitudinal axis of the excavation means or the axis of rotation
of the excavation means.
[0091] The excavation means can include a flushing fluid system or
drilling fluid system which operates to pump drilling fluid from
the excavation means or a portion there of, at a pressure of the
order of 50 psi to 500 psi.
[0092] The excavation means can include a shaped body or shaped
guides which locate the excavation means to excavate relative to or
along a pre-determined axis, which axis is located at an off-centre
location relative to the footprint of the caisson or casing or open
section retaining wall element or element of a formwork system.
[0093] The off-centre location can provide the extremities of a
locus or rotation envelope or excavation which clear the clutches
of a previously installed caisson or casing or open section
retaining wall element or element of a formwork system, and which
locus or rotation envelope or excavation extends past the forward
or opposite side clutches of the caisson or casing or open section
retaining wall element or element of a formwork system being
installed.
[0094] The excavation means can include a segmented construction
allowing the assembly to be increased or decreased in length to
suit different lengths of the caisson or casing or open section
retaining wall element or element of a formwork system being
installed.
[0095] The excavation means can be one of: a jet grouting tool; a
drilling tool; a reaming tool; a drilling and reaming tool.
[0096] The present invention also provides a method of inserting a
caisson or casing or open section retaining wall element or element
of a formwork system into a friable terrain, the method including
the steps of: arranging a drilling and/or reaming assembly as
described above, with respect to a caisson or casing or open
section retaining wall element or element of a formwork system;
positioning the drilling assembly and the caisson or casing or open
section retaining wall element or element of a formwork system over
a location for insertion of the caisson or casing or open section
retaining wall element or element of a formwork system; operating
the drilling assembly from another location, until the caisson or
casing or open section retaining wall element or element of a
formwork system has been situated as desired.
[0097] The method can also include the steps of: retracting the
expanding bits and/or reamers, and withdrawing the drilling and/or
assembly from the caisson or casing or open section retaining wall
element or element of a formwork system.
[0098] The method can also include the step of inserting or forming
a structural element into the caisson or casing or open section
retaining wall element or element of a formwork system.
[0099] The method can include the step of withdrawing the caisson
or casing or open section retaining wall element or element of a
formwork system.
[0100] The structural element can include a through aperture via
which grout is received to grout the structural element.
[0101] The method can further include the step of separately
drilling or reaming a hole into a hard ground at a position which
corresponds with the through aperture.
[0102] The through aperture can be adapted to receive a reinforcing
dowel.
[0103] The method can include the step of repeating the method to
insert further structural elements.
[0104] The method can further include grouting spaces between
adjacent structural elements.
[0105] The lateral vertical sides of the structural elements can be
shaped so that the grout between adjacent structural elements forms
a grout key.
[0106] A stocking made from canvas, plastic, any appropriate nylon,
or geo-fabric can be placed over a grout line used to grout spaces
between adjacent structural elements.
[0107] The method can further include the step of securing a
capping beam to the structural element or casting in situ a capping
beam.
[0108] The capping beam and structural element can be bolted or
screwed together.
[0109] The capping beam can include one or more inserted or
pre-cast reinforcement bars, each to be inserted into a
corresponding aperture in the structural element; or the structural
element includes one or more inserted or pre-cast reinforcement
bars, whereby each reinforcement bar is received by a corresponding
aperture in the capping beam; or the structural element includes
one or more inserted or pre-cast reinforcement elements, and the
capping beam is cast onto the structural element and around the
reinforcement elements.
[0110] The method can include securing an anchoring tie in the
capping beam.
[0111] The method can include the step of attaching a subsequent
caisson or casing or open section retaining wall element or element
of a formwork system to the caisson or casing or open section
retaining wall element or element of a formwork system.
[0112] The present invention also provides a retaining wall element
for use in controlling land erosion in contact with water which
comprises: self-supporting polymeric or metal construction, each
having a vertical longitudinal interior channel disposed therein
enclosed by at least three sides; each of the elements having a
pair of opposed faces to which are connected one or more fastening
means; each of the elements connected by mating engagement of the
at least one fastening means on one first element with at least one
fastening means on the at least one second element, the fastening
means being an engageable clutch or J-shaped hook; characterized in
that at least one of the elements includes in or on at least one of
a front wall and/or rear wall, an elongated fastening means
allowing the at least one element to connect to the ends of a wall
or walls of a casing or caisson and/or an excavation means, which
will be used to excavate and/or keep clear a volume in which the
element or elements will be installed in an underwater
location.
[0113] The fastening means on the front and/or the rear wall can be
an externally arranged engageable clutch or J-shaped hook.
Alternatively, the fastening means on the front and/or the rear
wall is an internally arranged engageable clutch or groove able to
receive a J-shaped hook.
[0114] The wall element can further comprise at least one end cap
having a fastening means to attach to the element.
[0115] The wall element can be constructed by its wall formation
shape and/or thickness to function as a structural wall when it is
in an open and/or hollow condition.
[0116] The wall element can be initially open and/or hollow and
when joined and assembled with like or similar elements, is then
used as an in-situ formwork and subsequently filled with concrete,
cement or grout, or filled with gravel to form a finished
structural wall construction.
[0117] The present invention additionally utilizes the technology
described in Australian patent applications 2016100200, 2016203790
and international application PCT/AU2016/051201, and the text and
drawings of these applications are incorporated herein.
IV. BRIEF DESCRIPTION OF THE DRAWINGS
[0118] A detailed description of a preferred embodiment will
follow, by way of example only, with reference to the accompanying
Figures of the drawings, in which:
[0119] FIG. 1.1 is a side elevational view of a caisson/casing and
drilling assembly with the drill bits in a retracted condition;
[0120] FIG. 1.2 is a front elevational view of the apparatus of
FIG. 1.1;
[0121] FIG. 1.3 is a plan view of the apparatus of FIG. 1.1;
[0122] FIG. 2.1 is a side elevational view of a caisson/casing and
drilling assembly with the drill bits in an extended or expanded
condition, showing how a substantial portion of the periphery of
the caisson/casing is overlapped by the drill bits;
[0123] FIG. 2.2 is a front elevational view of the apparatus of
FIG. 2.1;
[0124] FIG. 2.3 is a plan view of the apparatus of FIG. 2.1;
[0125] FIG. 3.1 is a side elevational view of a caisson/casing and
drilling assembly with the drill bits in an extended or expanded
condition with the middle bit lower than the outer bits and the
whole of the periphery is overlapped by the footprint of the drill
bits in extended or expanded condition;
[0126] FIG. 3.2 is a front elevational view of the apparatus of
FIG. 3.1;
[0127] FIG. 3.3 is a plan view of the apparatus of FIG. 3.1;
[0128] FIG. 4.1 is a side elevational view of a caisson/casing and
drilling assembly with the drill bits in an extended or expanded
condition, similar to FIGS. 3.1 to 3.3, with the middle bit being
at same height as the outer bits, but 90 degrees out of phase, and
the whole of the periphery is overlapped by the footprint of the
drill bits in extended or expanded condition;
[0129] FIG. 4.2 is a front elevational view of the apparatus of
FIG. 4.1;
[0130] FIG. 4.3 is a plan view of the apparatus of FIG. 4.1;
[0131] FIG. 5 illustrates a plan view of an embodiment similar to
that of FIG. 2.3, where the caisson/casing has a hollow
T-shape;
[0132] FIG. 6 illustrates a plan view of an embodiment similar to
that of FIG. 2.3 or 5, where the caisson/casing has a hollow
arcuate or half round shape;
[0133] FIG. 7 illustrates a plan view of an embodiment similar to
that of FIG. 2.3, 5 or 6, where the caisson/casing has is a
relatively large hollow square shape, utilizing some 9 expanding
bits;
[0134] FIG. 8.1 illustrates a side elevational view of a
caisson/casing and drilling assembly with two drill bits, both in
an extended or expanded condition;
[0135] FIG. 8.2 illustrates a plan view of the caisson/casing shown
in FIG. 9.1, where the caisson/casing is generally shaped like the
number "8";
[0136] FIG. 8.3 illustrates a front or rear elevational view of the
caisson/casing and drilling assembly shown in FIG. 8.1;
[0137] FIG. 8.4 illustrates a plan view of an embodiment similar to
that of FIG. 2.3, 5, 6, or 7 where the caisson/casing has the shape
shown in FIG. 8.2;
[0138] FIG. 9 illustrates a vertical cross section through the
embodiment of FIGS. 1.1 to 2.3 showing the assembly of a
caisson/casing and a drilling assembly with expanding drill bits
which are driven by hydraulic motors;
[0139] FIG. 10 are photographs of examples of two drill bits and
their specifications which can be utilized with the embodiments of
the invention;
[0140] FIG. 11 illustrates a dual section view of the drilling
assembly and its disengagement and retraction mechanism;
[0141] FIG. 12 illustrates a schematic view similar to FIG. 9,
except that intervening the between the lifting assembly and
latches is a hydraulic ram system to push the drilling assembly
downward relative to the caisson or casing;
[0142] FIG. 13.1 is a front or rear view of a plurality of
structural panels, drilling assembly, and grout between the
panels;
[0143] FIG. 13.2 is plan view of the panels of the apparatus of
FIG. 13.1;
[0144] FIG. 13.3 is a cross section through line 1-1 of FIG.
13.2;
[0145] FIG. 14.1 is a schematic front view of a plurality of
structural panels showing toe grouting of some of the panels;
[0146] FIG. 14.2 is a schematic plan view of FIG. 14.1;
[0147] FIG. 14.3 is a cross section through line 2-2 of FIG.
14.1;
[0148] FIG. 15.1 is a schematic cross sectional view of a plurality
of structural panels being attached to rock or hard ground;
[0149] FIG. 15.2 is a plan view of FIG. 15.1;
[0150] FIG. 15.3 is a cross section through line 3-3 of FIG.
15.2;
[0151] FIG. 16.1 is a schematic cross sectional view of a plurality
of structural panels and a capping beam attached to some of the
panels;
[0152] FIG. 16.2 is a schematic plan view of FIG. 16.1;
[0153] FIG. 16.3 is a cross section taken through line 4-4 of FIG.
16.2;
[0154] FIG. 16.4 depicts an alternative embodiment for attaching
dowels and a pre-cast capping beam to a panel;
[0155] FIG. 16.5 depicts an alternative embodiment for a capping
beam to a panel;
[0156] FIG. 16.6 depicts another alternative embodiment for
attaching the capping beam to a panel;
[0157] FIG. 17.1 is a front view of two caissons in situ, one of
which showing reinforcement bars;
[0158] FIG. 17.2 is a plan view of FIG. 17.1, schematically showing
concrete poured into the caisson as formwork;
[0159] FIGS. 18.1 and 18.2 are schematics depicting a capping beam
with land anchors or ties attached;
[0160] FIG. 19.1 is a schematic depicting the initial positions of
a drilling assembly and a caisson on a friable bed, preferably
under water;
[0161] FIG. 19.2 is a schematic depicting the movement of
plasticised or disturbed bed matter;
[0162] FIG. 19.3 is a schematic depicting the upward movement and
accumulation of plasticised bed matter as the caisson sinks;
[0163] FIG. 19.4 is a schematic depicting the downward movement of
plasticised bed matter once the caisson is removed;
[0164] FIGS. 20.1 to 20.8 are cross sections showing the method
where by a caisson inserted into a hole formed by the drill
assembly, and a second caisson is attached and inserted into the
hole;
[0165] FIG. 21 is a schematic view of a caisson which can be
vertically attached to another caisson;
[0166] FIG. 22 is a schematic view of a caisson which can be
lowered by the application of pulling forces.
[0167] FIG. 23 is a schematic plan view of three sheets of a
Larsson type 755 sheet pile wall showing the form and nature of the
clutch;
[0168] FIG. 24 is a schematic plan view of a caisson and drilling
tool attached to a first section of sheet pile already
positioned;
[0169] FIG. 24A is a schematic plan view of a pin or linkage system
to releasably connect the caisson and connections section of FIG.
24;
[0170] FIG. 25 is a schematic plan view of the caisson and tool of
FIG. 24 with the connecting section removed and the expandable bits
contracted;
[0171] FIG. 26 is a schematic plan view of the caisson of FIG. 25
with the tool removed;
[0172] FIG. 27 is a schematic plan view of the caisson of FIG. 26
with the second sheet attached to the first;
[0173] FIG. 28 is a schematic plan view of the first and second
sheets of FIG. 26 with the caisson removed;
[0174] FIG. 29 is a schematic plan view of a caisson and drilling
tool attached to the second sheet of FIG. 28;
[0175] FIG. 30 is a schematic plan view of the caisson and a first
sheet;
[0176] FIG. 30A is a schematic plan view of a pin or linkage system
to releasably connect the caisson and connections section of FIG.
30;
[0177] FIG. 31 is a schematic plan view of two sheets connected by
a cut to size bespoke joining sheet;
[0178] FIG. 32 is a schematic plan view of a first shape of
caisson;
[0179] FIG. 33 is a schematic plan view of a second shape of
caisson;
[0180] FIG. 34 is a schematic plan view of a third shape of
caisson;
[0181] FIG. 35 is a schematic front elevation of a sheet pile
wall;
[0182] FIG. 36 is an end elevation of a caisson constructing a
sheet pile wall;
[0183] FIG. 37 is an end elevation of a sheet pile wall.
[0184] FIG. 38 is a plan view of another caisson and drilling
assembly with a sheet pile releasably forming a part of the
caisson;
[0185] FIG. 39 is a schematic plan view of a pin or linkage system
to releasably connect the caisson and sheet pile section at the
left side of the assembly of FIG. 38;
[0186] FIG. 40 is a schematic plan view of a pin or linkage system
to releasably connect the caisson and sheet pile section at the
right side of the assembly of FIG. 38;
[0187] FIG. 41 is caisson and drilling assembly which has two drill
elements, which are able to be repositioned within the caisson or
casing;
[0188] FIG. 42 is the assembly of FIG. 41, showing the drilling
effect when the two drill elements are re-positioned within the
caisson or casing;
[0189] FIG. 43 is the assembly of FIG. 41 in a schematic cross
sectional view with the drill assembly being moved through the
caisson before reaching its drilling position, with the drill bits
retracted;
[0190] FIG. 44 is a plan view of the assembly of FIG. 43;
[0191] FIG. 45 is the assembly of FIGS. 43 and 44, in a schematic
cross sectional view with the drill assembly being in its drilling
position, with the drill bits extended;
[0192] FIG. 46 is a plan view of the assembly of FIG. 45 showing
the diameter of the bores drilled and/or of the radial reach of the
drill bits when extended;
[0193] FIG. 47 is the assembly of FIGS. 43 and 44, in a schematic
cross sectional view with the drill assembly being in its drilling
position after having been re-positioned, with the drill bits
extended;
[0194] FIG. 48 is a plan view of the assembly of FIG. 47 showing
the perimeter of the bores drilled by assembly in FIG. 47 and
previously drilled by the assembly in FIG. 45;
[0195] FIG. 49 is the assembly of FIGS. 43 and 44, in a schematic
cross sectional view with the drill assembly being retracted from
its drilling position of FIG. 47, with the drill bits retracted and
caisson advanced;
[0196] FIG. 50 is a plan view of the assembly of FIG. 49 showing
the diameter of the drill bits within the confines of the
caisson;
[0197] FIG. 50A illustrates a schematic plan view of another
connection section or piece;
[0198] FIG. 51 illustrates a schematic front elevation of a first
sheet pile placed to required depth and a second sheet pile
attached to the first sheet pile and driven to the top of a hard
seabed;
[0199] FIG. 52 illustrates a side elevation of the apparatus of
FIG. 51;
[0200] FIG. 53 illustrates a side elevation of the second sheet
pile with the combined excavation assembly and caisson or casing
attached and with the bits collapsed drilled to the top of the hard
seabed;
[0201] FIG. 54 illustrates the drill bits extended below the second
sheet pile;
[0202] FIG. 55 illustrates the second sheet pile after being
drilled into the seabed;
[0203] FIG. 56 illustrates the combined excavation assembly and
caisson or casing removed leaving the second sheet pile in
place;
[0204] FIG. 57 illustrates the second sheet pile grouted in place
and the soft seabed backfilled up to ground level.
[0205] FIG. 58 illustrates a schematic front elevation of a first
installed sheet pile with a second sheet pile with caisson or
casing and excavation assembly, shortly after the sliding
connection of the clutches between the first and second sheet;
[0206] FIG. 59 illustrates a side view of only the second sheet
pile and combined caisson or casing and excavation assembly with
drill bits in expanded state;
[0207] FIG. 60 illustrates the second sheet pile and combined
caisson or casing and excavation assembly with drill bits in
expanded state of FIG. 59, drilled into hard ground;
[0208] FIG. 61 Illustrates the unlocking of the drill assembly and
shaped wall from the sheet pile and sliding same up the sheet
pile;
[0209] FIG. 62 illustrates the sheet piled of FIGS. 58 to 61
grouted in place and land back filled to upper lip of the sheet
pile;
[0210] FIG. 63 illustrates a caisson (which extends to above water
level or soft bed level) and non-expanding drilling assembly, prior
to entry into water;
[0211] FIG. 64 illustrates the assembly of FIG. 63 sunk or pushed
or drilled through soft bed material to hard rock bed, and drilling
within confines of caisson just beginning drilling into hard
ground;
[0212] FIG. 65 illustrates the assembly of FIG. 64, with the drill
assembly down to depth;
[0213] FIG. 66 illustrates the withdrawal of the drilling assembly
from the caisson;
[0214] FIG. 67 illustrates the placement of the second sheet;
[0215] FIG. 68 illustrates the grouting and backfill of the second
sheet of FIG. 67;
[0216] FIG. 69 illustrates the caisson or casing and non-expandable
drilling assembly, with a curved connection section;
[0217] FIG. 70 illustrates the assembly of FIG. 69 with connection
section and drill assembly withdrawn or removed and corresponds to
FIG. 66;
[0218] FIG. 71 illustrates the placement of the second sheet inside
caisson and corresponds to FIG. 67;
[0219] FIG. 72 illustrates the second sheet connected to the first
sheet with the caisson removed and corresponds to FIG. 67, but is
prior to grouting and back filling;
[0220] FIG. 73 illustrates the caisson and drilling assembly
arrangement connected to the second sheet for guidance to drill for
the third sheet pile;
[0221] FIG. 74 illustrates a schematic plan view of the first
second and third sheet piles in grouted overlapping
excavations;
[0222] FIG. 75 illustrates a schematic plan view of a caisson or
casing and excavation footprint for use with interconnecting
concrete panels;
[0223] FIG. 76 Illustrates a schematic plan view of a connection
section for use with the system of FIG. 75;
[0224] FIG. 77 illustrates a schematic plan view of another caisson
or casing and excavation footprint for use with interconnecting
concrete panels with the caisson or casing using the earlier
positioned panel for guidance;
[0225] FIG. 78 illustrates a schematic plan view of further caisson
or casing and excavation footprint for use with interconnecting
concrete panels with the caisson or casing interacting with the
earlier positioned panel for guidance;
[0226] FIG. 79 illustrates a schematic plan view of further caisson
or casing and non-expanding drill bit excavation footprint for use
with non-interconnecting concrete panels with the caisson or casing
interacting with the earlier positioned panel for guidance;
[0227] FIG. 80 illustrates side view of the caisson and drilling
assembly of FIG. 79, showing the non-expanding drill bits;
[0228] FIG. 81 illustrates a schematic plan view of the placement
of a second concrete panel into the caisson and the excavation
footprint, before the caisson or casing is removed but after drill
assembly has been removed;
[0229] FIG. 82 illustrates a schematic plan view showing the first
and second concrete panels in place in the excavation
footprint;
[0230] FIG. 83 is a schematic plan view of a caisson or casing with
a drilling assembly with four expandable bits, which when expanded
are overlapping and within the footprint of the opening of the
caisson or casing;
[0231] FIG. 84 illustrates a schematic side view of the of the
apparatus of FIG. 83, showing the bits in expanded condition;
[0232] FIG. 85 is a view similar to that of FIG. 84, except that
the bits are shown in a contracted condition;
[0233] FIG. 86 is a schematic plan view of a caisson or casing with
a drilling assembly with four non expandable bits which are
overlapping and within the footprint of the opening of the caisson
or casing;
[0234] FIG. 87 illustrates a schematic side view of the apparatus
of FIG. 86, showing the bits;
[0235] FIG. 88 illustrates a plan view of the excavation foot print
within the Caisson or casing, with a pre-cast concrete panel
therein, as will be formed by the apparatus of either FIGS. 83 to
85 and/or 86 and/or 87.
[0236] FIG. 89 illustrates a caisson or casing and excavation means
or drilling assembly which has three excavation tools or drill
elements, representative of an odd number excavation tools or drill
elements, which excavate wholly within the caisson or casing, which
are able to be repositioned to produce an overlapping excavation
footprint;
[0237] FIG. 90 illustrates a caisson or casing and excavation means
or drilling assembly of FIG. 89 showing the drilling effect when
the three excavation tools or drill elements are re-positioned
within the caisson or casing;
[0238] FIG. 91 illustrates a caisson or casing and excavation means
or drilling assembly which has three excavation tools or drill
elements, representative of an odd number excavation tools or drill
elements, which excavate within and/or outside the caisson or
casing, which are able to be repositioned to produce an overlapping
excavation footprint;
[0239] FIG. 92 illustrates a caisson or casing and excavation means
or drilling assembly of FIG. 91 showing the drilling effect when
the three excavation tools or drill elements are re-positioned
within the caisson or casing;
[0240] FIG. 93 illustrates a caisson or casing and excavation means
or drilling assembly which has one excavation tool or drill
element, which excavate wholly within the caisson or casing, which
is able to be repositioned to produce an overlapping excavation
footprint;
[0241] FIG. 94 illustrates a caisson or casing and excavation means
or drilling assembly of FIG. 93 showing the drilling effect when
the excavation tools or drill element is re-positioned within the
caisson or casing;
[0242] FIG. 95 illustrates a caisson or casing and excavation means
or drilling assembly which has one excavation tool or drill
element, which excavate inside and/or outside the caisson or
casing, which is able to be repositioned to produce an overlapping
excavation footprint;
[0243] FIG. 96 illustrates a caisson or casing and excavation means
or drilling assembly of FIG. 95 showing the drilling effect when
the excavation tool or drill element is re-positioned within the
caisson or casing;
[0244] FIG. 97 illustrates a caisson or casing and excavation means
or drilling assembly of earlier Figures, which is being utilized
with two modular wall element or formwork such as the TRULINE
SEAWALL Modular wall system, so as to position such a modular wall
element or if used as formwork ready to receive poured or pumped
concrete or gravel.
[0245] FIG. 98 illustrates a caisson or casing being utilized with
a modified modular wall element or formwork;
[0246] FIG. 99 illustrates a caisson or casing being utilized with
another modified modular wall element or formwork;
[0247] FIG. 100 illustrates a schematic cross section in side view
(direction Y of FIG. 102) through a drilling and reaming apparatus
cooperating directly to a modular wall element of FIGS. 97 to
99;
[0248] FIG. 101 is a schematic cross sections in side view
(direction Z of FIG. 102) of the system of FIG. 100, where the
drilling and reaming apparatus has expanded;
[0249] FIG. 102 illustrates an underneath view of the arrangement
of FIG. 100, with the drill bit 4 removed for illustration
purposes;
[0250] FIG. 103 illustrates an underneath view of the arrangement
of FIG. 101 with the drill bit 4 removed for illustration
purposes;
[0251] FIG. 104 is a schematic side view cross section through a
drilling and reaming apparatus as used with the drilling and
reaming assembly of FIGS. 101 and 103, showing different levels of
the multiple reaming elements;
[0252] FIG. 105 is a schematic side view cross section through a
drilling and reaming apparatus as used with the drilling and
reaming assembly of FIGS. 100 and 102, in the process of being
withdrawn from a wall element;
[0253] FIG. 106 illustrates a side view cross section of the drill
head;
[0254] FIG. 107 illustrates a schematic plan view of the multiple
equi-spaced reaming elements of the drill assembly of FIG. 104;
[0255] FIG. 108 illustrates a side sectional view of part of the
drilling and reaming assembly;
[0256] FIG. 109 illustrates a plan view of the part of the off-set
drilling and reaming assembly of FIG. 108;
[0257] FIG. 110 is a schematic plan view of a three sided modular
wall element installed in a cavity drilled by a twin drive shaft
system based on the drilling and reaming system of FIGS. 100 to
109;
[0258] FIG. 111 is a schematic plan view of a four sided modular
wall element installed in a cavity drilled by a twin drive shaft
system based on the drilling and reaming system of FIGS. 100 to
109;
[0259] FIG. 112 is a schematic plan view showing the geometry of a
three sided modular wall element installed in a cavity drilled by a
single drill drilling system of FIGS. 100 to 109;
[0260] FIG. 113 is a schematic plan view of an alternative caisson
or casing interacting with a modular wall element;
[0261] FIG. 114 is a schematic front or side view of a drilling
assembly contained within a body or section, whether hollow or
solid, the outside of which is shaped to match the shape of a
modular wall element; and
[0262] FIG. 115 is a schematic sectional view of the drilling
assembly of FIG. 114 through the section plane A-A.
V. DETAILED DESCRIPTION OF THE EMBODIMENT OR EMBODIMENTS
[0263] The description and claims relate to the use of caissons or
casings, and caissons and casings, to place structural elements
into ground while minimizing disturbance of the surrounding
environment. For the purpose of this specification and attached
claims, the word "caisson" is meant to describe a hollow structure,
which can be pressurized, that is, able to bear hydrostatic
pressure either as water is evacuated from inside, or air is pumped
in, whereas the word "casing" is meant to describe a hollow
structure which is not pressurized, that is, water may be on the
inside of the hollow structure. The following description applies
to both types unless it is specified otherwise.
[0264] While the following description is in respect of an
unpressurised caisson or casing, driven vertically in marine
sediment it will be readily understood that the invention and
embodiments thereof can be applied to pressurized caissons, and in
directions other than vertical and other ground types.
[0265] Illustrated in FIGS. 1.1 to 1.3 is a generally rectangular
caisson or casing 1, which can be of any desired height and/or wall
thickness. Inside of the caisson or casing 1 is mounted an inner
drilling assembly 3 with thee drill bits 4, being in a retracted
condition. Not shown in these Figures are the attachment of the
inner drilling assembly to the caisson or casing, or the bit drive,
or flushing mechanism, but they are illustrated and described in
respect of FIG. 9. The drill bits 4 are mounted for rotation in the
drilling assembly 3, as described later in respect of FIG. 9. It
will be noted from FIGS. 1.1, 1.2 and 1.3 that the retracted size
or diameter of the drill bit 4 that is selected for use with the
caisson/casing 1, is such as to fit within the inner wall dimension
of the caisson/casing 1. The expansion and retraction of the
cutting edges can be achieved by rotation, or by mechanical,
hydraulic, or other means.
[0266] Illustrated in FIGS. 2.1 to 2.3 are a similar Figures to
FIGS. 1.1 to 1.3 respectively, showing the relative positioning of
the caisson/casing 1's wall with the drill bits 4.1 being the same
as drill bits 4, except in an extended or expanded condition. It
should be noted that the drill bits now labeled 4.1 in their
extended or expanded condition do not cover the complete leading
edge 2 of the caisson/casing 1, as is visible in each of FIGS. 2.1
to 2.3. However, it will be noted that a substantial portion of the
periphery of the caisson/casing perimeter is overlapped by the
outside diameter of the extended or expanded drill bits 4.1. In
soft ground or highly friable terrain, this will not hinder the
advance, downward movement or insertion of the caisson/casing 1's
into such ground.
[0267] The caisson or casing 1 does not rotate whilst it is
advanced or inserted into the ground. The terrains in which the
embodiments are used are friable ground whereby the "cuttings" or
bed are disturbed or plasticized, fluidized or worried, and are
displaced by the drilling assembly and/or the caisson or casing.
The embodiments do not drill or function when rock is encountered.
The cuttings in these terrains are simply disturbed or moved away,
and mixed with water by the rotation action of the drilling bits 4,
especially in e.g. a river bed. This enables the caisson or casing
to sink into the ground and reach the required or predetermined
depth, under the influence of gravity, by a pushing or a pulling
force, or by hammering. For instance, as shown in FIG. 22, workers
can apply a tension rather than a compressive force to lower the
caisson. This can be done by pulling on a rope, cable or similar
38, which is arranged around pulleys 40 to transmit the pulling
force into a downward force upon the caisson or casing 1.
[0268] The drill assembly 3 effectively closes off, or
substantially closes off, the opening formed by the inner periphery
at the leading ledge of the caisson or casing.
[0269] It will be noted from FIGS. 2.2 and 2.3, that the outside
diameter of the expanded drill bits 4.1 do not overlap, ensuring
the easy operation and obviates the need to synchronize the bits
4.1 in their cutting action.
[0270] As the bits 4.1 when expanded, can be contracted to the
positions shown in FIGS. 1.1 to 1.3, this means that when the
caisson/casing 1 is in the desired position in the earth, river or
harbour bed, or other location, once brought to the retracted
condition can be withdrawn from the caisson/casing 1, with the
friction with the caisson/casing 1 outer wall, ensuring that it
does not move when the drilling assembly 3 is withdrawn from the
caisson/casing 1.
[0271] Illustrated in FIGS. 3.1 to 3.3 are respectively similar
views to that of FIGS. 2.1 to 2.3 with the drill bits 4.1 and 4.2
in their extended or expanded conditions covering the complete
leading edge 2 or the whole periphery of the caisson/casing 1.
Drill bit 4.2 is vertically positioned lower with respect to the
bits 4.1, so that the rotation of bit 4.2 does not conflict with
the rotation of other bits 4.1. Alternatively, the bit 4.2 can be
positioned above other bits 4.1, in order to achieve a similar
functional effect.
[0272] Illustrated in FIGS. 4.1 to 4.3 are respectively similar
illustration to that of FIGS. 3.1 to 3.3, with the drill bits 4.3
in their extended or expanded position, but the outer bits 4.3
being at a 90 degrees phase difference to the inner bit 4.3. The
rotation of the drill bits in this assembly would need to be
synchronized to avoid conflict or inter-engagement. The
synchronization could be achieved by chains, gears or any other
appropriate means.
[0273] Illustrated in FIGS. 5, 6 and 7 are caissons 1 and inner
drilling assemblies 3 of various shapes. The location of the drill
bits 4.1 are as detailed in FIGS. 2.1 to 2.3. The drill bits 4.1 of
FIGS. 5, 6 and 7, could also be arranged as described in FIGS. 3.1
to 3.3 or 4.1 to 4.3.
[0274] Illustrated in FIGS. 8.1 to 8.4 are a caissons/casing 1 and
an inner drilling assembly 3 of the shape which generally
corresponds to the number "8". Two drilling bits 4.1, 4.2 are
provided in the drilling assembly 3. The drilling bits 4.1, 4.2, in
their expanded condition overlap with each other. Therefore, one
drill bit 4.2 is positioned lower than the other drill bit 4.1.
[0275] It will be readily understood that structural elements of
other shapes than those illustrated in the FIGS. 1.3, 3.3, 4.3, 5
to 7, and 8.3 will require caissons/casings 1 of other
corresponding or matching shapes.
[0276] As illustrated in FIGS. 1.1 to 8.4, there is a gap 2.1
between the body of the inner drilling assembly 3 and the interior
surface of the caisson or casing 1. The body of the inner drilling
assembly 3 can further generally conform to the shape of the
interior of the caisson 1. This gap is usually of the order of 5 to
10 millimeters, but variations from this range are possible. When
the embodiment is used in a watery environment such as the ocean,
harbour, or river, water is allowed to ingress into the interior of
the caisson/casing 1 through the gap 2.1. Water ingress into the
caisson or casing 1 is also possible through any other apertures or
holes provided on the wall of the caisson or casing 1. Thus in
circumstances where the embodiment is used in a watery environment,
water is allow to enter and may fill the caisson/casing 1. The
water ingress helps the caisson/casing to sink into the friable
ground.
[0277] Illustrated in FIG. 9 is a caisson/casing 1 and an inner
drilling assembly 3 with three expanding drill bits 4 driven by
hydraulic motors 5. The motors 5 are kept in approximate
synchronization by the hydraulic flow divider 7. The flow divider 7
can be located within the inner drilling assembly 3 or as shown in
FIG. 9 where it is external to the caisson/casing 1. The motors 5
have drive shafts 6 that pass through bearings 8 to the bits 4.
[0278] Flushing hoses 14 supply air or liquid to the bits 4 through
the bearing 8 and the shaft 6 to a location past the base 9 of the
bearing 8, and out through the flushing hole 15. Hydraulic hoses 13
connect the divider 7 with the motors 5. A latch assembly 10 on the
drilling assembly 3 locates the inner drilling assembly 3 with the
caisson/case 1, and engages apertures 11 in the caisson or casing
1. A lifting assembly 12 is provided to remove the inner drilling
assembly 3 from the caisson/casing 1 when the bits 4 are retracted.
The lifting assembly 12 is connected to the latch assembly 10 so
that when tension is applied to the lifting assembly the latch 10
will automatically detach from the caisson 1. This attachment is
not shown on the drawings.
[0279] In operation, the periphery of the body of the drilling
assembly 3 conforms as close as practical to the internal rim of
the leading edge of the caisson 1, which will preferably, on its
inside, be of a constant cross section. This relationship of
conformity precludes or reduces the entry of material into the
caisson 1. The drill bits 4, by their rotation, will worry,
plasticize, fluidize, or disturb the ground. The disturbance can be
also helped or enhanced by the injection of fluids through the
flushing hole 15. The ground, so disturbed, is forced by the
combined mass of the caisson 1 and the drilling assembly 3 to move
outward from underneath the drilling assembly 3 and upward as the
assembly sinks.
[0280] Illustrated in FIG. 10 are examples of two drill bits which
are available and can be used with the embodiments described above.
Other types of expanding drill bits, some called under the name
`reamers" or "under reamers" which may or may not require rotation
to cause expansion or counter-rotation to cause contraction, are
also known which can also be used with the embodiments of the
present invention as described above.
[0281] In respect of the above embodiments, when the caisson or
casing 1 has reached the required depth, the rotation of the
expanding drill bits 4, 4.1, 4.2, 4.3 are reversed in the direction
16 of FIG. 10, retracting the cutting edges. The inner drilling
assembly 3 can then be detached from the caisson/casing 1 and then
removed from the caisson/casing 1. Once the required depth of
caisson/casing 1 is reached, a structural element, such as a poured
concrete element (such as a wall, a block, retainer), or a
preformed concrete shape, can then be formed or placed inside the
caisson/casing 1 and then caisson/casing 1 removed leaving the
structural element in position, and allowing the caisson/casing 1
to be re-used.
[0282] The structural elements placed inside the caisson/casing 1
can be made from concrete, steel or any other material, and may
include reinforcing made from fibre glass or non-corroding
reinforcing material.
[0283] The structural element can be provided with a drain hole, or
drainage holes.
[0284] The drainage holes in the structural element can be provided
with a strip drain. The strip drain can be protected by geo
fabric.
[0285] The structural element can be provided with a lifting eye,
or lifting eyes so it can be lifted and deposited into position in
the caisson/casing 1.
[0286] The structural element can be provided with a grout tube, or
tubes to allow grout, or other medium, to be pumped to the base.
The grouting can be done before during or after the withdrawal of
the caisson/casing 1.
[0287] The structural element can be provided with a void or a
multiple of voids to allow a jet grouted pile, or piles to be
constructed below the element.
[0288] The structural element can be provided with a void, or voids
to allow the installation of a grouted rock dowel, or dowels below
the element. The structural element can also be provided with
reinforcement bars to allow attachment of a capping beam. The
structural element can also be provided with cast in place
penetrations, i.e. through apertures, to allow the reinforcement
bars to be grouted in place after casting.
[0289] After the structural element is placed in the caisson/casing
1, a free flowing material either granular or liquid can be placed
in the caisson as it is withdrawn to fill the void left by the
caisson/casing 1. The caisson or casing could alternatively be left
in situ, as a final structural element. Furthermore, the caisson or
casing could also be used as formwork, to e.g. form or cast in
place a concrete structural element.
[0290] In respect of the description of what is positioned inside
the caisson/casing 1, after it has achieved a desired depth, as
described above in paragraphs [0072] to [0080] has not been
described in any detail, nor illustrated, as these aspects are not
part of the invention described in this specification, and further
will be commonly and widely known by a person skilled in this
art.
[0291] Illustrated in FIG. 11 is a manual release system to
separate the drilling assembly 3 from the caisson/casing 1. In this
manual release system the lifting cable 12 connects to a lifting
flange 12.1. The left side of FIG. 11 shows the system when the
drilling assembly 3 is locked by latches 10 to latch holes 11 thus
locking the two together. The lifting flange 12.1 has a lifting
bolt 12.3 which passes through an upper frame member or component
of the drilling assembly 3, and is secured in place with an
intervening compression spring 12.2, washer 12.4 and nut 12.5. The
lifting flange 12.1 has a pivot connection 10.3 to pivotally
connect the latch body 10.1, and the latch body 10.1 is pivotally
connected by pivot 10.2 to the mounting plate 10.4 which is secured
to the drilling assembly 3. Thus, according to the right hand side
of FIG. 11, when the lift assembly 12 applies sufficient force to
the lifting flange 12.1, so as to overcome the spring force of the
spring 12.2, this will move the bolt 12.3 upward relative to the
drilling assembly 3, which causes a rotation of the latch body 10.1
around relatively stationary pivot 10.2, thus withdrawing the latch
10, out of latch hole 11, thus allowing the drilling assembly 3
being able to be withdrawn from and relative to the caisson/casing
1.
[0292] Illustrated in FIG. 12 is a caisson/casing 1 and drilling
assembly 3, which is similar to that of FIG. 9, and like parts have
been like numbered. The difference is that the drilling assembly 3
is able to be moved downward relative to the caisson/casing 1, by
means of spaced hydraulic or pneumatic cylinders 100, which push or
pull against the lifting frame 12, which is held in place by the
latches 10 in latch holes 11 in the caisson/casing 1. The same
pushing and pulling force could be provided by a similar apparatus
external to the caisson or casing 1. At a desired depth, the
cylinders 100 are energized to extend so as to push (or pull) the
drilling assembly 3 downward. By retracting the cylinders 100, the
caisson/casing 1 can be pulled downward into the drilled hole. Then
the drills active again, pushed downward by the extending cylinders
100 etc.
[0293] It will be noted from FIGS. 1 to 11 that the body of the
drilling assembly 3 is of a shape and size which effectively, or
substantially, closes off the opening formed by the inner periphery
of the caisson or casing 1. This is the case whether the caisson or
casing 1 is of a rectangular or curved shape, or whether of a more
complex shape such as an arc or T-shape.
[0294] It is to be noted, from the embodiments depicted, that there
are two or more drilling heads used to create an area that
generally overlaps with the opening or footprint of a caisson or
casing having a single opening.
[0295] FIGS. 13.1 to 13.3 depict a method of grouting the vertical
spaces between inserted precast panels. FIG. 13.1 shows a casing or
caisson 1 which is advancing downwardly, aided by the action of the
drill bits 4. As discussed previously, once the drilling bits 4 and
caisson/casing 1 advance to the required depth, the drill bits 4
are retracted and removed. The caisson or casing 1 supports any
pre-existing sea-walls nearby or adjacent, while a preformed
structural panel 17 is inserted into the caisson/casing 1, before
the caisson/casing 1 is removed. When this process is repeated and
a further panel is inserted adjacent the first panel, a gap in the
form of a vertical space 17.1 will be left between the panels
17.
[0296] To seal or close the gaps 17.1, the panels 17 will be
grouted. To do this, a stocking 18 is placed over a grout line 19
to be inserted in a gap 17.1 between the panels 17. The stocking 18
can be chosen from materials such as canvas, plastic, any
appropriate nylon, or geo-textile. The grout line 19 is then pushed
to the bottom of the gap 17.1. As the grout material is being
pumped into the gap 17.1, the grout line 19 is withdrawn. As shown
in FIG. 13.2, the panels 17, on their vertical side edges, have
grooves or formations. As the grout is pumped, the material
conforms to the space formed by the grooves or formations between
adjacent panels 17, and forms a key 20 between adjacent panels
17.
[0297] FIGS. 14.1 to 14.3 depict a method of grouting the toes or
lower portions of the structural panels 17. The drilling assembly 3
and the caisson/casing 1 are larger than the panels 17. Therefore,
after the caisson/casing 1 is withdrawn, the panel 17 is
encapsulated by the disturbed ground. Grouting the toes or lower
portions of the panels 17 in the ground will enhance the stability
of the panels 17. A grout tube 21 is precast in each panel 17. The
grout tube 21 runs the whole length of height of the panel 17.
Grout 22 is pumped into the grout tube 21. The grout 22 used for
toe grouting generally has a specific gravity of approximately 2,
which is higher than the specific gravity of the disturbed,
plasticised, worried, or fluidized portion of the friable ground.
As the grout 22 is denser than the disturbed, plasticised, worried,
or fluidized ground, the pumped grout will displace the disturbed
ground to encapsulate the corresponding panel 17. The grout 22 is
pumped after the casing is taken out to at least the desired grout
height. The volume of the grout 22 to be pumped will therefore be
determined by the difference between the desired grout height
multiplied by the difference between the cross sectional area of
the resulting hole and the cross sectional area of the panel. Once
this is done, the grouting procedure of FIGS. 13.1 to 13.3 can be
employed to key in or lock adjacent panels together.
[0298] As shown in FIGS. 15.1 to 15.3, in some situations, one or
more of the panels will be placed over rocks or hard-ground 24
which is not friable or not friable enough. The caisson/casing 1
will not sink into the hard ground 24. A panel 17 suitable for
placement over hard ground 24 can have cast into it a penetration
23, i.e. a through aperture. The penetration 23 is usually
centrally located with respect to the panel 17. The rock cutting
drill bit 4 is then operated to drill a hole 25 into the hard
ground 24 through the penetration 23, so that a hole 25 is drilled
to coincide with the penetration 23. A reinforcement dowel 26 can
be placed into the hole 25, and grouted in place through the grout
line 27 which extends to the bottom of the hole 25.
[0299] Any reinforcements are preferably of a non-corrodible type
material, such as glass fibre, reinforcing carbon fibre rods or
stainless steel, etc.
[0300] FIGS. 16.1 to 16.6 depict securing or casting a capping beam
28 to the tops of the structural panels 17. As shown in FIG. 16.1
to FIG. 16.3, the structural panels 17 can have blind apertures or
penetrations 29 accessible from the tops of the panels 17 Separate
reinforcement bars 30 adapted to be partially received by the blind
apertures 29 are grouted into place in the apertures 29.
Alternatively, the panels 17 can have reinforcement bars 31 cast
into them. A capping beam 28 which has been pre-cast is then
attached to the dowels 30, or alternatively the capping beam is
cast onto the dowels 30. The capping beam 28 will have holes which
correspond to the reinforcement bars 30, 31. The reinforcement bars
30, 31 are fitted into the corresponding holes in the capping beam
28 as the capping beam 28 is attached. FIG. 16.4 depicts the
reverse scenario, where inserted dowels 30 or precast dowels 31 are
provided in a pre-cast capping beam 28. The capping beam 28 is then
attached to the panels 17 which have the required apertures to
accept the dowels 30, 31.
[0301] More preferably, as shown in FIG. 16.5, the capping beam 28
can cast directly into a formwork provided around the tops of the
panels 17, in which case the capping beam 28 will be cast around
the dowels 30, 31 and the panels 17. As shown in FIG. 16.6, it is
alternatively possible to cast a capping beam 28 onto the panels 17
or attach a precast beam 28 to the panels 17, and then drill
securing bolts to secure the beam 28 and panels 17 together.
[0302] FIGS. 17.1 and 17.2 depict concrete caissons or casings 1
that are formed with reinforcements 1.3 and that are left in situ
rather than removed, after the drilling assembly 3 has been
retracted. The caissons are left as structural elements. The
caisson/casing 1 may or may not have a structural core. It can be
left in situ as a structural element itself, or it may have a cast
in place concrete structural core 1.2 that is formed inside the
caisson 1.
[0303] Referring to FIGS. 18.1 to 18.2, the panels 17 or capping
beams 28 further include anchoring ties 32 to stable land which is
adjacent the panels 17. In FIG. 18.1, holes are drilled into the
adjacent stable land to insert the ends of the ties that are distal
from the panels 17. The proximal ends of the ties are bolted or
otherwise secured to the capping beams 28 or panels 17. The
anchoring ties 32 helps secure the panels 17 against the weight of
the friable land pushing directly or indirectly against the panels
17. In FIG. 18.2, the panels 17 are installed next to wall members
17.2 which are pre-existing and deteriorating, with the panels 17
being put in place to shore up or take over from the old
pre-existing retaining panels 17.2. In this case, an old anchor
32.2 is already in place and tied to adjacent land. An extension
32.1 is linked to the old anchor 32.2 to extend the tie 32 to the
capping beam 28 for the new panel 17. The extension 32.1 can be
precast into the beam 28, or the capping beam 28 for the new panel
17 is post tensioned to the existing capping beam 28.2.
[0304] FIGS. 19.1 to 19.4 depict the movement of the bed dirt, mud,
or other matter which is displaced by the drilling assembly 3. As
discussed before, as the drilling assembly 3 drills into the
friable ground, the weight of the caisson/casing 1 enables the
caisson 1 to sink down to the drilled level. As mentioned above,
the caisson 1 is also able to sink because the cuttings tend to be
displaced upwards. Together the actions and weight of the drilling
assembly 3 and caisson 1 progressively cause portions of the
friable ground to become plasticised, which allows the action of
gravity to sink the caisson to a desired depth.
[0305] The assembly 3 and caisson 1 displace the disturbed or
drilled matter 33, which tends to accumulate upwards as shown in
the arrows included in FIGS. 19.2 and 19.3. The arrows of FIG. 19.3
depict the process whereby, as the caisson and drilling assembly
advance deeper into the hole, more disturbed or drilled matter 33
is accumulated upwardly. The previously displaced cuttings or
matter is pushed upwards by newly displaced matter. Once the drill
assembly is retracted, and a structural element such as a panel 17
is inserted into the caisson 1, the caisson can be removed. Upon
the removal of the caisson 1, the previously piled displaced matter
33 (if toe grouting is not done) now flows downwardly, in the
direction indicated by the arrows in FIG. 19.4, to fill the space
vacated by the caisson 1. Due to the friable nature of the
environment, the drillings and cuttings are plasticized. Therefore,
there is no requirement to actively pump the bed matter out of the
drilled hole to prevent blockage.
[0306] Referring to FIGS. 20.1 to 20.8, in some circumstances, the
depth of the hole to be drilled will be greater than the length or
height of a caisson 1 that can be used with the drilling equipment.
In this situation, additional caissons 1' can be added to follow
the initial or leading caisson 1 which has been inserted or
partially inserted into the hole, in an end-to-end fashion. Here,
the attachment of the caissons 1, 1' is done whilst the trailing
edge of the first inserted caisson 1 is still accessible.
Preferably, the neighbouring caissons 1, 1' will be attached
together. This way, the plurality of caissons 1, 1' is able to be
removed in a single operation. The skilled person will appreciate
that more caissons can be added for insertion into holes of greater
depths as needed.
[0307] FIG. 21 is a schematic view of one manner of attachment
between neighbouring caissons. As shown, the lower or leading
caisson 1 has a rim, flange, bead, or generally a projection 34
around its trailing edge. The adjacent, subsequently inserted
caisson 1' which trails the other caisson 1 includes a cooperating
projection 35 at its leading edge. The cooperating projection 35
includes a groove 36 which is adapted to receive the trailing
projection 34 of the previous caisson 1. The upper or subsequent
caisson 1' is further constructed from two halves 1'-1, 1'-2,
respectively having the grooves 36-1, 36-2. The two halves 1'-1,
1'-2 are two vertical halves of the subsequent caisson 1'. The
halves 1'-1, 1'-2 have a vertical parting plane S and are initially
spaced apart from each other. The vertical halves 1'-1, 1'-2 are
moved toward the trailing edge of the first or previously inserted
caisson 1, then closed toward each other and onto the previously
inserted caisson 1, so that the grooves 36-1, 36-2 together are
fitted onto the projection 34, attaching the caissons 1, 1'
together. The two vertical haves 1'-1, 1'-2 of the subsequent
caissons 1' can further be secured together by e.g. bolts. The
skilled person will appreciate that although the subsequent
caissons or casings 1' are described as having two half sections,
they can each be constructed of three or more vertical sections,
and then assembled in the manner described above.
[0308] When the caissons 1, 1' need to be removed, the upper most
caisson 1' is hooked or otherwise attached to a lifting device, and
then both caissons 1, 1' will be lifted together because of the
attachment between the caissons 1, 1'.
[0309] The caissons 1, 1' can have identical features--that is each
caisson 1 has a leading projection 35 and a trailing projection 34
as described above, and is constructed from two vertical halves.
This construction allows the subsequent caisson 1' to be added
unhindered by the support or cables for the drilling assembly.
Alternatively, the skilled person will appreciate that the first
inserted caisson does not need to have a leading edge projection 35
or be constructed from multiple sections.
[0310] While the preceding passages describe prior art systems,
these systems are particularly useful together with the following
inventive aspects and embodiments, as described below with respect
to FIGS. 23 to 50.
[0311] In broad terms, the embodiments illustrated in FIG. 24, FIG.
28, FIGS. 32 to 34 and FIGS. 51 to 62, all provide a caisson or
casing 107 for installing a sheet 102 into a ground or underwater
location, the caisson 107 having a shaped wall 107.1 which is open
for a predetermined length, which is adapted to receive and connect
to an excavation means 3 within the confines of the caisson or
casing 107.
[0312] The shape of the shaped wall 107.1 will be dependent upon
the sheet pile or other retaining wall element that needs to be
positioned in ground or under water location. The shaped wall can
be made from any number of wall segments needed to match the shape
of the sheet pile being installed. So, for the shaped wall 107.1 of
FIG. 24, there are segments 107.2 to 107.10, while shaped wall
107.1 of FIGS. 32 to 34 have segments 107.2 to 107.8, and the
shaped wall 17.1 in FIG. 38, is made from three segments 107.2 to
107.4. In the case of the FIGS. 24 and 32 to 34 shaped walls, these
almost entirely match the shape of the sheet pile 102 being
installed.
[0313] The shaped wall 107.1 has its free sides A and B each having
a clutch, and a connecting section 125 or 111, in the case of the
systems of FIGS. 24, 30, 38, 50A and 69 is provided which closes
the caisson 107 and or the shaped wall 107.1.
[0314] The connection section 125 or 111 (as seen in FIG. 30) can
have a first wall portion 125.1 with a mating clutch 125.2 and
125.4 to join with the clutches at the free sides A and B of the
shaped wall 107.1.
[0315] The connection section 125 of FIGS. 24 and 38 also include a
second wall portion 125.10 which is at an angle to the first
portion and which terminates in at least one element mating join
formation or clutch, in this case a third clutch 125.11 which is
adapted to engage the free clutch at a side of a sheet 101
previously inserted in the ground or underwater location.
[0316] The connection section 125, as in the case of FIG. 38, is a
sheet pile, which is adapted, in use, to be separable from the
shaped wall 107.1.
[0317] The connection section 125, in the case of FIG. 38 has a
first clutch 125.2 and a second clutch 125.4, the first clutch
125.2 located at a side of the connection section 125 and the
second clutch 125.4 located intermediate the free sides 125.10 and
125.1 of the connection section 125, so that the first and second
clutches 125.2 and 125.4 are adapted to connect to the two clutches
at the free sides A and B of the shaped wall 107.1.
[0318] The connection section 125 has the element mating join
formation or clutch 125.11 located at the other side of the
connection section 125 from the first clutch 125.2, with the
element mating join formation or clutch 125.11 being adapted to
engage a free clutch being at a side of a sheet 101 previously
inserted in the ground or underwater location.
[0319] The element mating join formation or mating clutch 125.11 on
the connection section 125, by being adapted to engage a free
clutch on a sheet 101 previously inserted in the ground or
underwater location, is adapted to act as a guide to guide the
caisson or casing 107, and an excavation means 3 combined
therewith, as excavation or drilling occurs.
[0320] The element mating join formation or clutch 125.11 is
adapted to be located outside an excavation footprint 108 of an
excavation means which is at the end of the caisson or casing 107,
but remains within the excavation footprint 105 of the ground
disturbed when placing sheet 101.
[0321] The caisson or casing 107, as best illustrated in FIGS. 24A,
30A and 39 have a releasable locking mechanism 300 which allows
releasable interconnection between the connection section 125 and
the shaped wall 107.1.
[0322] The locking mechanism 300 can include any lock mechanism,
such as a pin means like shear pin 126, which sits in aligned
apertures passing through mating clutches on the shaped wall 107.1
and the connection section 125, in which case it will be a clutch
locking mechanism, which can be removed when needed. The apertures
can be of any appropriate shape, and the pin can simply match that
shape. However this is not preferred due to the importance of the
clutch allowing relative sliding motion. Alternatively, and more
preferred, as illustrated in FIGS. 24A, 30A and 39 one of the
connection section 125 or the shaped wall 107.1 can be provided
with a flange portion 125.13 provided to receive the removable pin
126. The locking mechanism 300 is preferably at the top and/or
bottom of both ends of the shaped wall 107.1 so that when it is
upended, a lock between the clutch on the shaped wall 107.1 and the
sheet 102/103 can be effected.
[0323] The caisson or casing 107 when combined with an excavation
means 3 can be adapted to allow the excavation means 3 to provide
an excavation footprint 108 which can overlap an excavation
footprint 105 related to the sheet 101 previously inserted in the
ground or underwater location.
[0324] After the caisson or casing 107 has been positioned in the
ground or underwater location, the connection section 125 is
separable from the shaped wall 107.1, by the mechanisms described
above.
[0325] The shaped wall 107.1 is adapted so that a sheet 102 can be
made to engage the clutch of a previous sheet 101, and pushed or
hammered or vibrated into position.
[0326] The shaped wall 107.1 is removeable from the ground or the
underwater location, after the sheet 102 is positioned.
[0327] The drilling assembly as described in relation to FIGS. 1 to
22 can be combined with the caisson or casing 107 of FIGS. 23 to
50.
[0328] The excavation means 3 substantially closes off an opening
formed by an inner periphery of the caisson or casing 107, even
though in the embodiment of FIGS. 32 to 34, there is an open side
to the caisson or casing 107.
[0329] As best illustrated in FIGS. 24 and 38 there are multiple
excavation means 109 used for the caisson or casing opening.
[0330] The excavation means 109 excavates hard ground or drills
hard ground, allowing the caisson or casing 107 to be positioned to
a predetermined or required depth.
[0331] As the connection section 125 has to be separated from the
shaped wall 107.1, there needs to be provided means, such as
releasable lock means 10 described above, which can disconnect
them. The connection section 125 preferably does not connect to the
excavation means 3 or releasably connected to the excavation means
3 or.
[0332] It may be preferred that the excavation means 109 to be
associated with the caisson or casing 107, be connected to or
supported only by the shaped wall 107.1.
[0333] When installing the "first" sheet pile 101.1, as best
illustrated in FIG. 30, then either the a first caisson 107 shaped
and sized specifically to accept the first sheet 101.1 can be
utilized. In a first example the sheet 101.1 will be a standard
width sheet pile, and the caisson 107 of FIG. 30 having increased
dimensions when compared to that of FIG. 24 which is being used to
install a subsequent sheet pile. Alternatively the same caisson 107
from FIG. 24 can be used, but a first sheet 101.1 can provided
which has a reduced width, so that the sheet pile 101.1 fits within
the caisson 107 and connection piece 111.
[0334] As is described above in respect of FIGS. 1 to 22, the
embodiments of FIGS. 23 to 50 are constructed so as to attach an
excavation tool 3 within the lower end of the caisson 107. The tool
3 is shaped to fit inside the caisson 107 being used. The tool 3
consists of two or more drill bits (which may not be expandable) or
two or more expandable drill bits 109 arranged so as in their
expanded state they excavate beyond the boundary of the caisson or
casing 107.
[0335] The drill bits 109 are provided with a means of flushing the
hole with a fluid. The fluid may be, water, polymer, mud or any
other suitable fluid. When rotated in the expanded state the drill
bits will allow the caisson 107 to advance to the required depth,
through hard ground, without noise or vibration.
[0336] When the required depth is reached the expandable drill bits
are returned to their retracted state. In this state they are
contained entirely within the caisson 107. The tool 3 can then be
detached and removed from the caisson 107.
[0337] When the tool 3 has been removed, in the manners described
above with respect to FIG. 1 to 22, the first sheet 101 or 101.1
can be placed to the correct depth inside the caisson 107.
[0338] When the first sheet 101 being full sized positioned by the
caisson 107 or first sheet 101.1 being of reduced size positioned
by the first caisson 107, is in place, then caisson 107, or the
first caisson 107, can be removed and a second caisson assembly 107
will now be required, due to the change in shape of the sheet pile
102. The second caisson 107 is shaped so as to accept the second
sheet 102. The second caisson 107 is also shaped to fit the tool 3.
The second caisson 107 can be in two parts, a connecting section
125 and a main body or shaped wall 107.1. The connecting section
125 can be attached to the first sheet 101 or 101.1 by the clutch
and to the body by two clutches 125.2 and 125.4 or by other
convenient means.
[0339] In the systems of FIGS. 23 to 37, the connecting section 125
of the caisson 107 attached to the first sheet 101 is removed
leaving the body or shaped wall 107.1 of the caisson 107 in
place.
[0340] With the connecting section 125 and the tool 3 removed, then
a second sheet 102 can be attached to the first sheet 101 and
placed to the correct depth. With the second sheet 102 in place the
shaped wall 107.1 of the caisson 107 can be removed.
[0341] If in the installation of the piles a smaller first pile
101.1 is used then the first caisson can now be re-used to install
a third pile. Or if a first caisson and second caisson have already
been used, then a third caisson assembly 107 will now be required.
It will be similar to the second caisson 107 but a mirror image.
This caisson 107 is shaped to fit the third sheet 103.
[0342] The third caisson, as described above is advanced, without
noise or vibration, and the tool 3 removed.
[0343] The third sheet 103 can be attached to the second sheet 102
and placed to depth. The third caisson 107 can then be removed.
[0344] By repetition of the steps described above a sheet pile wall
can be constructed in hard ground without noise or vibration.
[0345] Those skilled in the art will understand that utilizing
several caissons 107 and possibly multiple drilling tools 3 will
slow down the installation process. Whereas it can be speeded up if
the process used a single tool and a single caisson assembly. The
connecting section 125 of the second caisson could be replaced by a
blank part so that the assembly took the shape of the first
caisson, or something similar.
[0346] Alternatively, the shaped wall 107.1 can be constructed so
that the second caisson assembly 107 could be turned upside down,
thereby allowing it to take the shape needed for the of the third
caisson assembly. Likewise if the tool 3 is constructed
symmetrically about its minor axis it will fit both a right hand
and a left hand caisson.
[0347] Those skilled in the art will understand that sheets can be
fabricated with the clutch misaligned. This will allow the next
sheet to be placed at an angle to the XX axis. By this method sheet
pile walls, other than straight can be constructed.
[0348] After the sheet piles 101, 102, 103 etc. have been placed in
position, the base of the sheets 101, 102, 103 etc. can be grouted
into the hole that has been drilled. A polymer or bentonite drill
fluid will greatly assist this process. This grouting should take
place some distance behind the advancing pile wall under
construction and should not be allowed to impinge on the drilling
of the caisson for the next sheet.
[0349] While the following description is in respect of one section
of sheet pile it will be readily understood that the present
invention can be applied to other sections.
[0350] While the following description is in respect of placing one
sheet at a time it will be readily understood that the present
invention can be applied to install multiple sheets at one
time.
[0351] FIG. 23 shows three sheets 101, 102 and 103 connected by
clutches 104. The sheet pile 101, 102 and 103 in this instance is
Larsson type 755 sheet pile. For the purpose of this description
the sheets 101, 102 and 103 are to be installed in numerical order.
The longitudinal axis XX is shown for reference
[0352] FIG. 24 shows the first sheet 101 in place. The boundary of
the ground disturbed or drilled during the installation of the
first sheet 101 is shown by the intermittent line 105. The
connecting section 125 of the caisson 107 attaches to the first
sheet 101 by clutch 125.11 which connects to the clutch 104 on the
first sheet 101. The other end of connection piece 125 connects to
the body or shaped wall 107.1 of the caisson 107 by two clutches
125.2 and 125.4 to the clutches at the ends A and B.
[0353] In FIG. 24, a drilling tool 3 is shown attached inside the
caisson 107. The attachment of the tool 3 to the caisson 107 is not
shown, but is as described above in relation to FIGS. 1 to 22. Four
drills 109 with expandable drill bits are located within the tool
3. The boundary 108 is the limit of the ground disturbed by the
drill bits 109 in their expanded state. It should be noted that the
connection section 125 has its clutch 125.11 beyond the boundary of
the disturbed ground 108 but it is inside the boundary of the
previously disturbed ground 105. It should also be noted that the
boundary 108, that is, the limit of the expanded bits, passes close
to, but does not interfere with the first sheet 101. The tool 3 is
symmetrical about the minor axis YY. The inner void of the caisson
107 is shaped to match the symmetry about the axis YY, but is not
actually symmetrical. This relationship and arrangement allows the
caisson 107 and the tool 3 to be used when the caisson 107 is in a
mirror reverse configuration. This will be necessary to place sheet
103.
[0354] For the purpose of the following description the caisson 107
will be viewed along the YY axis from the point it coincides with
the XX axis. FIG. 24 is thus described as a caisson 107 with a
right hand interconnection. A caisson 107 with a left hand
connection will be required to place sheet 103. The caisson 107
with the tool 3 attached and the expanding bits 109 in their
expanded state, extending to the boundary 108, can now be drilled
to the required depth.
[0355] FIG. 25 shows the caisson 107 after it has been drilled to
the required depth and the interconnecting section 125 removed. The
tool 3 has been collapsed so that it is now contained within the
caisson 107. In this state the tool 3 can be detached and removed
from the caisson 107.
[0356] FIG. 26 shows the caisson 107 with both the interconnecting
section 125 and the tool 3 removed. The caisson 107 can now accept
sheet 102.
[0357] FIG. 27 shows the second sheet 102 connected to the first
sheet 101 inside the empty caisson 101. The sheet 102 can then be
pushed to the correct depth. The caisson 107 can then be
removed.
[0358] FIG. 28 shows the second sheet 102 connected to the first
sheet 101 and the caisson 107 removed.
[0359] FIG. 29 is similar to FIG. 24 but the assembly is now a
caisson 107 with a left hand interconnection shaped to accept sheet
103. The change in handedness can be provided either by turning
both the caisson 107 and the connection piece 125 upside down or it
could be a purpose built caisson. Note that because the void in the
caisson 107 is symmetrical about the YY axis, the tool being also
symmetrical about the YY axis will fit inside the caisson 107 as
before, once it has been rotated through 180 degrees.
[0360] The process of drilling the caisson 107 to the correct
depth, removing the connection piece 125, detaching and removing
the tool 3, placing the next sheet 103 and removing the caisson 107
can now be repeated.
[0361] FIG. 30 shows the caisson 107 with a blank connection piece
111 in place drilled to depth and the tool 3 removed. This caisson
107 can be manufactured in one piece but in this configuration it
could be used to place the first sheet 101. The purpose of the
blank connection piece 111 is so the caisson 107, in conjunction
with the tool 3, can be used to place sheets 101 and subsequently
with connection piece 125 of earlier Figures, used to place the
second sheet 102 and third sheet 103. The fabricated first sheet
101 is shown inside the caisson 107. The caisson 107 and the
connection 111 can be withdrawn leaving the sheet 101 in place to
the correct depth.
[0362] FIG. 31 shows the closure of a sheet pile wall. A fabricated
sheet pile piece 114 is used to connect sheet 112 to the last full
sheet 113 both positioned in the ground. The fabricated connecting
piece 114 is able to be placed because the disturbed ground shown
by the intermittent lines 115 and 116 overlap. To arrive at this
position sheet 113 may have to be fabricated with a reduced width
as sheet 101 or 101.1 in FIG. 30.
[0363] FIG. 32 is similar to FIG. 27 except it shows a caisson 107
shaped to accept a different sheet pile section, in this instance
Larsson type ZK 675 sheet pile. The caisson 107 is shown with the
connecting piece 125 removed. The sheet 102 is shown connected to
the previously placed sheet 101.
[0364] FIG. 33 shows a caisson 107 shaped to accept Larsson type ZK
675 sheet pile. This caisson 101 is open sided, with no connecting
piece being used. In certain types of ground this may be
possible.
[0365] FIG. 34 shows a caisson 107 shaped to accept Larsson ZK 755
sheet pile. This caisson 107 is open sided, in that between the
ends A and B it is open, but are shaped to be directed inwardly to
the sheet pile 101, to more closely fit to the previously placed
sheet 101. If desired, the sheet pile 101 can have welded or
attached locating blocks or locating flanges 101.2 and 101.3, so as
to provide a guide for the inward ends A and B to travel between.
In certain types of ground this may be possible, and is expected to
work effectively, when the sheet pile is installed shortly after
the drilling has been completed.
[0366] As can be seen from the above description, in broad terms
there is described a method of inserting a sheet or sheet pile 102,
103, the method including: providing a caisson or casing 107 as
described above; providing an excavation means 3 which is
expandable to excavate and retractable to within the confines of
the caisson or casing 107; utilizing an earlier installed sheet
pile 101, 101.1 a drilling guide or if the caisson or casing is
open, overlapping the excavation area of the new sheet pile 102
with that of the earlier installed sheet pile 101; installing a
sheet pile 102 or 103 by means of the caisson or casing.
[0367] The method described above includes the use of a connection
section 125 or 111 to close the caisson or casing or shaped wall
107.1.
[0368] The connection section 125 enables the caisson or casing 107
to be guided by the earlier installed sheet pile 101. As
illustrated in FIG. 50A it can be seen that the connection section
125 could also be constructed from a V-shaped type of construction
where the free legs include the clutches 125.2 and 125.4, and the
vertex of the V has the clutch 125.11 extending from it.
[0369] The connection section 125 as in the case of the embodiment
of FIG. 38 also acts as a sheet pile 102 and remains in the ground
or underwater location.
[0370] FIG. 35 shows previously placed sheet 101 which has
penetrated a hard layer of ground 117. The caisson 107 attached to
sheet 101 has drilled through the hard ground 117 and with the tool
3 (not shown) removed, and can now accept the next sheet 102 (not
shown on the drawing). Once placed through the hard ground inside
the caisson 107, the sheet 102 can be placed to depth by
conventional means- that is, this apparatus is such that it does
not require the caisson 107 to move down further. Ground level 118
is shown.
[0371] FIG. 36 shows a caisson 107 which has drilled through a
layer of soft ground 121 and then into a hard sea bed 119. Water
level 120 is shown.
[0372] FIG. 37 shows the sheet pile 102 which has been place
through the caisson 107. After the caisson 107 has been removed
grout 122 can be pumped to the bottom of the drilled hole in the
seabed 119. The sheet 102 is now grouted into the drilled hole in
the seabed 119. The pile 102 is now able to support the ground 121.
Up to ground level 118. Water level 120 is shown.
[0373] Illustrated in FIG. 38 is another sheet pile installation
system and method.
[0374] The caisson 107 is effectively constructed in two halves.
The first half being a shaped wall 107.1 to accept the drilling
tool 3. The second half being a connection section 125, which will
also be the sheet 102 to be installed. A clutch 125.4, or other
means of attachment, must be adhered or riveted in the case of some
sheet pile material, or welded if steel or aluminium, or by sheet
bolts in the case of GFRP, to one side of the connection piece 125
or sheet to be installed. The first half 107.1 of the caisson 107
will attach to the second half 125 by this clutch and the existing
clutch on the other side. The two halves now forming one caisson
can be attached to the clutch 104 of the previously placed adjacent
sheet 101, by means of the clutch 125.11 located on the end of the
sheet pile 125/102. As before the drilling tool 3 is shaped to fit
inside this caisson 107.
[0375] FIG. 38 shows a section of clutch 125.4 welded to one side
of the sheet to be placed 102. This clutch 125.4 can be continuous
or it can be intermittently present and engaging depending upon the
application. The sheet to be placed 102 is attached to the
previously placed adjacent sheet 101. The shaped wall 107.1 or
caisson half is attached to the sheet 102 to be placed by both the
welded clutch section 125.4 and the existing clutch on the other
side. The two halves now form one caisson. Inside this caisson 107
is the drilling tool 3 with four expandable drills 109, with the
drilling tool 3 being attached to the lower end of the caisson 107.
When the drilling tool 3 is in the expanded state the boundary of
the ground disturbed 108 is beyond the caisson 107. The caisson 107
can now be drilled to depth. When the caisson 107 has been drilled
to the correct depth the expandable drill bits 109 can be
collapsed. When the bits 109 have been collapsed both the drilling
tool 3 and the caisson half or shaped wall 107.1 can be withdrawn
separately or in unison. The result being that the sheet 102 has
been positioned in the required place.
[0376] The caisson half or shaped wall 107.1 is then upended and
combined or attached to the next sheet 103 not shown on the
drawing. As the drilling tool 3 is symmetrical about the YY axis,
after it is rotated through 180 degrees, it can again be attached
to the lower end of the caisson and the drilling process
repeated.
[0377] As described earlier, the excavation means 3 is detachably
attached to the caisson 107 or the shaped wall 107.1, and is
preferably a drilling tool 3 comprised of two or more drill bits
109, such as expandable drill bits. In the expanded state the
drilling tool 3 excavates beyond all, or substantially all, of the
boundary of the lower end of the caisson 107. In the collapsed
state the drilling tool 3 is contained wholly within the foot print
of the hole or aperture through the lower end of the caisson 107.
The excavation means 3 is positioned so as to close off all, or
substantially all, of the lower end of the caisson 107. The
excavation means 3 being detachably connected to the caisson 107
ensures that when attached to the caisson 107, the caisson 107 will
advance as the tool 3 drills. When the drilling tool 3 is detached
it can be removed from the caisson 107. The excavation means 3 will
generally be provided with or connected to a source of flushing
air, water, polymer, mud or a combination of any 2 or more of
these.
[0378] Illustrated in FIGS. 41 to 50 is an excavation means 3 for
use with a caisson or casing 1 so as to drill in front of the
leading edge of the caisson or casing 1, particularly in hard
ground. The excavation means has a body to mount at least two
excavation tools 133 so that the two excavation tools 133 are
distanced or spaced from each other so that the outside diameter
134 of excavation of the tools 133 are spaced from each other so
that when the body 3 is rotated through 180 degrees, a series of
overlapping excavations will result. The excavation means includes
a detachable connection, as described above, to a caisson or casing
with which it will be used. The advantage of the excavation means 3
is the ability to drill a shaped hole with less drill bits.
[0379] The excavation means 3 is a drilling tool or drilling tool
assembly, and can include expandable drilling bits, and there can
be an even or an odd number of bits or excavation tools 133, as is
illustrated in FIGS. 91 and 92, or a single excavation tool 133 as
illustrated in FIGS. 95 and 96. It will be noted in the case of the
excavation or drilling assemblies 3 of FIGS. 41, 42, 91, 92, 95 and
96, that there is located one excavation tool 133 close to a side
wall of the drilling assembly so as to be close to the side wall of
the caisson or casing 1, but there is a larger spacing to the
opposite side wall, from the only or last excavation tool 133.
[0380] In summary, FIGS. 43 to 50 show a method of drilling a
caisson or casing 1, the method including the steps of: providing a
caisson or casing 1; attaching to the caisson or casing an
excavation means 3; advancing the excavation means 3 to excavate
ground beneath the excavation means 3; withdrawing the excavation
means 3 from the caisson or casing; rotating the excavation means
through 180 degrees; reattaching the excavation means 3 to the
caisson or casing 1; advancing the excavation means 3 to excavate
ground beneath the excavation means 3 to produce a series of
overlapped excavations into which the caisson or casing 1 can
positioned.
[0381] The following will describe FIGS. 41 to 50 in more
detail.
[0382] FIG. 41 illustrates a plan view of an alternative caisson 1
with a main body of a drilling assembly 3 located inside. The
assembly 3 has two expanding drills 133, in their collapsed state,
attached. The attachment of the drills 133 is asymmetrical. It will
be noted that the caisson 1, is similar to that of FIGS. 1 and 2
above, except that in FIGS. 1 and 2 above show three drills 4,
whereas the caisson 1 of FIGS. 41 to 50 has only two expandable
drills 133 which are spaced apart, so that when rotated by 180
degrees, a series of four bores 134 and 135, as depicted in FIG.
42, will be drilled.
[0383] FIG. 42 shows the same plan view as that of FIG. 41, when
the expanding drills 133 are expanded to their outer diameter 134
in their expanded state. The broken circles 135 illustrate the
holes to be drilled next, once the drill tool 3 has been removed
from the caisson, then rotated through 180 degrees, and drilling
begins again.
[0384] Illustrated in FIGS. 43 to 50 is a schematic representation
of the drilling process. FIGS. 43 and 44 is a schematic side
elevation and a plan view respectively of a caisson 1 containing a
drill assembly 3 with the expanding drills 133 in their collapsed
state, which have not yet been locked to the caisson 1, and have
not yet arrived into the position for the drill 3 and caisson to be
detachably secured together. In the position of FIG. 43, the
assembly 3 is ready to advance to the drilling location.
[0385] FIGS. 45 and 46 are similar to FIGS. 43 and 44, and show the
drill assembly 3 after it has advanced, and with the drills in the
expanded state. Once Drilling occurs, two holes will be drilled
which coincide with the drilling diameter circles of FIG. 46, and
the holes will be spaced apart, whereby only part of the periphery
of the caisson 1 will have a drilled holed underneath its leading
edge.
[0386] Once the two holes have been drilled, the caisson and drill
assembly of FIGS. 45 and 46 will then have the drill bits collapsed
and the drill tool 3 removed from the caisson 1. The drill tool 3
once out of the caisson is then rotated through 180 deg. When
viewed in plan view and placed back into the caisson 1, ready to be
advanced.
[0387] FIGS. 47 and 48 shows the caisson and drill assembly 1 and 3
after the drill tool 3 has been advanced the second time. The
drills 3 are then returned to their collapsed state and the caisson
1 advanced.
[0388] FIGS. 49 and 50 shows the caisson 1 advanced and the drill
tool or assembly 3 collapsed ready to repeat the steps of FIGS. 43
to 50, but starting on the right side of the caisson.
[0389] Illustrated in FIGS. 51 to 57 is a sheet pile placement
method and apparatus, similar to that described above. In this
method the first sheet pile 101 is in position to a required depth
in hard ground 119 having also passed through soft bed 121. It is
called "first" only for the sake of ease of description, as it will
be seen in FIG. 51 that the first sheet pile 101 connects to an
even earlier unnumbered sheet pile. It will also be noted in FIG.
51, that the hard ground to the right of the base of the sheet pile
101 has been excavated by the earlier used excavation tool.
[0390] The second sheet pile 102 is connected to sheet pile 101 by
their respective clutches, and the sheet pile 102 is pushed down
through the soft layer 121 until its base reaches the start of the
hard ground layer 119, as in FIGS. 51 and 52.
[0391] In FIG. 53 a shaped wall 107.1 and drill assembly 3, are
assembled together with a trailing leg 3.1 which is preferably
connected to the drilling assembly 3, but may be extending from the
shaped wall 107.1. The shaped wall 107.1 has clutches 125.2 and
125.4 to engage clutches provided on the sheet pile 102 (such as
described above in relation to FIG. 38), with the drilling bits
109, which are schematically represented by a single bit, being
operated without expanding, and "drilling" through the soft bed
121, until it reaches the hard ground 119.
[0392] As seen in FIG. 54, once the hard ground 119 is engaged, the
expanding bits continue to drill, until they pass sufficiently the
lower end of the sheet 102, and then they are reversed and they
slowly expand outwardly as they drill and undercut the leading edge
of the sheet 102. The point at which the expanding bits 109 can be
reversed and expanded is when an engagement end 3.2 on the trailing
leg 3.1, engages the top edge 102.9 because the distance between
the end 3.2 and the drill bit 109 has been set for the height of
the sheet 102.
[0393] The end 3.2 also has the advantage that as the drill
assembly 3 moves down the sheet pile 102, all the while being
guided by the sheet 101, the sheet 102 follows the drill assembly 3
downward until, drilling is finished as in FIG. 55. Whereupon the
drill assembly and shaped wall 107.1 and leg 3.1 and end 3.2 are
withdrawn as in FIG. 56, and the sheet pile 202 grouted in place
(once a further sheet along the wall has been installed), and then
eventually as in FIG. 57 the ground level side 118, can be back
filled to complete the wall construction.
[0394] This arrangement of FIGS. 51 to 57 has the advantage that
the shaped wall 107.1 does not need to be locked to the sheet 102
by means of the clutches that are engaged, making the process
quicker. Additionally the caisson or casing 107 formed by the
shaped wall 107.1 and sheet 102, at the base of the sheet 102,
assists to ensure that soft bed 121 does not rush to fill in the
excavation foot print. It will be noted that the Shaped wall 107.1
is of a height greater than the depth of soft bed 121 and the depth
of drilling into hard ground, thus keeping out soft bed material
while drilling is occurring
[0395] Illustrated in FIGS. 58 to 62 is a sheet pile placement
method and apparatus, similar to that described above. In this
method the first sheet pile 101 is in position to a required depth
in hard ground 119 having also passed through soft bed 121. It is
called "first" only for the sake of ease of description, as it will
be seen in FIG. 58 that the first sheet pile 101 connects to an
even earlier unnumbered sheet pile. It will also be noted in FIG.
58, that the hard ground to the right of the base of the sheet pile
101 has been excavated by an earlier used excavation tool.
[0396] In the method of FIGS. 58 to 62, as in FIGS. 58 and 59, a
drilling assembly 3 and shaped wall 107.1 are operatively connected
to a sheet pile 102, so that the drilling bits 109 when expanded
are below the leading edge of the caisson 107 formed at the lower
section of the sheet 102 by the joining of the shaped wall 107.1 to
the sheet pile 102, by one of the means described above The height
of the shaped wall is provided so that it is higher than the depth
to be drilled in hard ground 119 plus the depth of the soft bed
121.
[0397] In FIGS. 58 to 62, the drill bits 109 are schematically
represented by a single drill bit 109. At the top 102.9 of the
sheet 102 is a conventional sheet pile installation tool or piling
equipment 139, which will drive the sheet pile 102 and drill
assembly and shaped wall 107.1 through the soft bed 121, until hard
ground 119 is encountered. The shaped wall 107.1 and drill assembly
are joined together, and the assembly of them is connected to the
sheet 102 by a releasable latch mechanism 10 (such as that
described above), which is shown I the locked condition in FIG.
59.
[0398] Thus as the piling equipment 139 pushes the sheet 102 into
the soft bed 121, so too does the shaped wall and drilling assembly
follow. If needed depending upon the "viscosity" of the soft bed
121, the unexpanded bits in the drill assembly can be rotated in an
unexpanded condition to help clear the path for the shaped wall
107.1 and the drilling assembly 3.
[0399] Once hard rock is reached the bits 109 are rotated so as to
expand under the leading edge of the shaped wall 107.1 and the
sheet pile 102, and continues to drill until the required depth is
reached, as illustrated in FIG. 60. At this point, as illustrated
in FIG. 61, the sheet 102 is at its required depth, and the piling
equipment 139, by means of lifting assembly 12, and the
disengagement of latch 10, lifts the drilling assembly 3 with the
drill bits unexpanded and shaped wall 107.1, up along the sheet 102
and out ready for the next sheet. Then as in FIG. 62, grout 122 can
be installed in both the soft bed 121 and hard ground layers 119,
and the ground level 118 back filled to the wall so produced, but
usually a few sheet back if back filling is progressing at the same
time as pile placement is occurring.
[0400] Illustrated in FIGS. 63 to 74, is a sheet pile installation
method and apparatus similar to that of FIGS. 24 and 29, except
that the caisson or casing 107 and its shaped wall 107.1 has a
modified shape, and the connection section 125 too is modified in
shape. Additionally the drilling assembly 3 has some 5 drills to
insert a sheet pile 102.
[0401] Illustrated in FIG. 63, the caisson 107 of FIG. 69 is
combined by a latch 10 to the drilling assembly 3, preferably
before insertion into the water 120. The caisson 107 and drill
assembly 3 are then sunk to the hard ground layer 119 through soft
bed 121. This can be done by pushing through the soft bed 121 or
simply rotating the non-expanding drill bits 109 until hard bed 119
is reached, as illustrated in FIG. 64.
[0402] As illustrated in FIG. 65, the latch 10 is released allowing
the drilling assembly to continue drilling through the caisson 107,
until the desired depth of placement has been reached. It will be
noted from FIGS. 64 and 65 that the height of the caisson 107 is
greater than the depth below water level 120 of the hard rock layer
119. By this means water and softer bed 121 do not go back into the
caisson protected area.
[0403] Once drilling to the required depth is completed, the
drilling assembly 3 and latch 10 can be removed from the caisson
107, as is illustrated in FIG. 66, and then as in FIG. 67, the next
sheet pile 102 joined to the earlier pile 101, and slid into
position inside the caisson 107. The caisson 107 can then be
withdrawn. Then as in FIG. 68, after the installation of sheets has
progressed, the base hole can be grouted and the ground level back
filled at appropriate time in the installation process.
[0404] As best illustrated in FIG. 69 the caisson 107 used in FIGS.
63 to 68 has a shape to receive 5 drills 109 which are
non-expanding drill bit, and will have an excavation p footprint
that will allow a sheet pile 102 to be installed before the caisson
is removed, and after the drill assembly is disconnected and
removed from the shaped wall 107.1. It will be noted that the
connection section 125 has a curved wall shape at the ends of which
are clutches 125.2 and 125.4, and at an intermediate location is
attached clutch 125.11. It will be noted that he left hand most
drill 109, has its left most excavation footprint overlapping the
earlier drill footprint 105 associated with installed first sheet
pile 101.
[0405] The connection section 125 is removed immediately before the
sheet pile 102 is to be inserted as in FIG. 67, in which case the
arrangement of FIG. 70 is adopted where the drilling assembly 3 has
been removed and overleaping footprints 105 and 108 are present,
leaving a generally open space for insertion of the second sheet
pile 102 to be inserted in the caisson 107 by joining respective
clutches to sheet 101, as illustrated in FIG. 71.
[0406] Then, as in FIG. 72, the caisson 107 is removed, being a
step between FIGS. 67 and 68, the sheet piles 101 and 102 are
sitting in their respective excavation foot prints. This will allow
the sheet pile 101 to be grouted into position, while the caisson
107 (or the shaped wall 107.1 and the connection section 125) on
the surface has been up-ended (that is rotated around a horizontal
axis) and the drill assembly 3 has been rotated through 180 degrees
around a vertical axis and re-assembled to begin to repeat the
steps of FIGS. 63 to 68, this time appropriately oriented for the
placement of sheet pile 103, as is illustrated in FIG. 73. The
repeating of steps 63 to 68 will produce a wall segment as
illustrated in FIG. 74, whereby the excavation foot print will have
been grouted with grout 122 to secure the respective piles 101,102
and 103 into their holes.
[0407] Illustrated in FIGS. 75 and 76 is a method and apparatus for
installing slidingly interlocking concrete panels 17, which have a
male key 17.3 and female key or recess 17.4 at opposite ends. The
method and apparatus is similar to that described previously in
relation to sheet piles, and employs a generally rectangular open
shaped wall 107.1, which can be closed off by a connection section
125 as illustrated in FIG. 76. The connection section 125 has a
male key portion 125.11, which will engage recess 17.4 on an
earlier positioned panel 17 to guide the drilling process. The
drill assembly 3, will include expanding drill bits to drill ahead
of the leading edge of the caisson 107, forming excavation
footprint 108 which will overlap with the previously drilled
footprint 105. Then like the method of FIGS. 63 to 68, the
connection section 125 is removed, and the next panel 17 can be
lowered into positon to join up with the earlier installed panel
17.
[0408] Illustrated in FIG. 77 is another method and apparatus for
installing a concrete panel 17, similar to that of FIG. 75, except
that no connection section 125 is used. Instead the shaped wall
107.1 simply has an open end in which the right hand side of panel
17 can be located to assist with the guidance of the drilling
process. As the shaped wall 107.1 is longer than in FIG. 75, the
footprint 108 will readily overlap with foot print 105, allowing
another panel 17 to be installed.
[0409] Illustrated in FIG. 78 is a method and apparatus similar to
that of FIG. 77, except that the concrete panel 17 includes a
vertical channel or recess 140 on each side of the panel 17 near to
the end of the panel 17 which has the recess 17.4. The recess 140
is a guide recess to receive the turned in ends of the shaped wall
107.1, and in this way to act to assist in the guiding of the
drilling process.
[0410] Illustrated in FIGS. 79 to 82 is method and apparatus for
installing concrete panels 17, which are similar to that of FIG.
78, in that at one end they have vertical guide recesses 140 near
one end, but are not interlocking. Additionally, the drilling
assembly 3, does not utilize expandable bits, that is drilling
occurs only within the confines of the shaped wall 107.1. The drill
bits 109 are located at different heights as shown in FIG. 80, and
as in FIG. 81, once the drilling assembly 3 has been removed,
allowing a seme shaped panel 17 to be dropped into place in the
shaped wall 107.1, abutting the previously inserted concrete panel
17. While no joining of adjacent panel 17 may be done under water,
a capping beam 28 as described above, and other joining can be done
above water level once the shaped wall 107.1 has also been removed
as in the case of FIG. 82, where the panels 17 are ready to be
capped.
[0411] In the case of each of the methods and apparatus of FIGS. 75
to 82, it is preferred to disconnect the drilling assembly 3 from
the shaped wall 107.1, and to take out the drilling assembly 3
before dropping in the next panel 17. This allows the shaped wall
107.1 to keep out soft bed 121 from lowing into the drilled hole.
However, if the apparatus of FIGS. 75 to 78 were used to drill into
hard ground 119 only, that is there was not present a soft bed 121,
the shaped wall 107.1 and the drill assembly 3 can be removed
together, thereby saving time by saving process steps.
[0412] In broad terms, as illustrated in FIGS. 83 to 88 is an
excavation means 3 and a caisson or casing 1 for insertion into
soft bed or friable ground, with the excavation means 3 being able
to excavate inside the opening or opening footprint of said caisson
or casing 1. The excavation means 3 having a body to mount at least
two excavation tools 4.2 or 4.2' so that a series of overlapping
excavations 108 will result. The excavation means 3 includes a
detachable connection to said caisson or casing 1.
[0413] There are one or a multiple number of excavation tools 4.2
or 4.2' illustrated in FIGS. 83 to 88, in this case two, which are
distanced from each other so that the outside diameter of
excavation of the tools are spaced from each other so that when the
body of the drilling assembly 3 is rotated through 180 degrees, the
excavation that occurs producing an overlapped excavation footprint
108. However, as illustrated in FIGS. 89 and 90, there can be an
odd number of tools 4.2 or 4.2', or as is shown in FIGS. 93 and 94,
a single excavation tool. It will be noted in the case of the
excavation or drilling assemblies 3 of FIGS. 83 to 88, 90, 91, 93
and 94, that there is located one excavation tool 4.2, 4.2' close
to a side wall of the drilling assembly 3 so as to be close to the
side wall of the caisson or casing 1, but there is a larger spacing
to the opposite side wall, from the only or last excavation tool
4.2, 4.2'.
[0414] The excavation means can be a drilling tool or drilling tool
assembly 3.
[0415] The excavation means 3 can includes: only expandable
drilling bits 4.2; or only non-expanding drill bits 4.2'; or a
combination of expanding drilling bits 4.2 and non-expanding drill
bits 4.2' where the expanding drill bits 4.2 when expanded have the
same outside diameter of the non-expanding drill bits 4.2'.
[0416] There is also described a method of drilling a caisson or
casing 1 in a soft bed or friable ground, whereby the method
includes the steps of: providing a caisson or casing 1 and an
excavation means or assembly 3 as described in the preceding four
paragraphs. The method then allows for activating the excavation
means 3 to excavate ground beneath said excavation means 3 so as to
produce a series of overlapped excavations 108 within the opening
or opening footprint of the caisson or casing 1, whereby the soft
bed or friable ground allows the caisson or casing and the
excavation means or drill assembly to move through it.
[0417] Describing now in more detail, illustrated in FIGS. 83 to 85
is another caisson or casing 1 and drilling assembly 3, which is
similar to that of FIGS. 1 and 2 described above, except that there
are four drill bits 4.2 which are expandable, but when expanded,
are fully within the internal periphery of opening footprint of the
caisson or casing 1. The bits 4.2 are arranged or spaced so that
when expanded as in FIG. 84, they overlap, and occupy different
height positions as depicted in FIG. 85. It will be noted from FIG.
84 that the overlapping of the drilling bits 4.2 occupies a
substantial surface area of the footprint of the opening of the
caisson or casing 1. Whereas when the drill bits 4.2 are contracted
or retracted, they occupy the smaller diameter circles in FIG. 83,
and this is reflected illustrated in the side view of FIG. 85. This
caisson 1 and drilling assembly 3, is meant to perform its drilling
operation wholly within the confines of the caisson's opening or
opening footprint, and is particularly suitable where soft bed
material is encountered or needs to have a for example a pre-case
concrete panel 17, as depicted in FIG. 88.
[0418] Illustrated in FIGS. 86 and 87 is a caisson or casing 1 and
drilling assembly 3, which is similar to that of FIGS. 83 to 85,
except that the drill bits 4.2' are not expandable. In that respect
it is also similar to the caisson and drilling assembly of FIG. 79,
except that the caisson 1 of FIG. 86 has a fully bounded
rectangular caisson or casing and thus does not directly act or be
guided by the previous panel 17 whereas caisson or casing 107 of
FIG. 79 has a shaped wall with an open section to interact with the
previous panel 17. The drill bits 4.2' overlap each so that they
are fully within the internal periphery of opening footprint of the
caisson or casing 1. The bits 4.2' are arranged or spaced so they
overlap, and occupy different height positions as depicted in FIG.
85. It will be noted from FIG. 86 that the overlapping of the
drilling bits 4.2' occupies a substantial surface area of the
footprint of the opening of the caisson or casing 1.
[0419] While not illustrated, if desired, the caisson 1 can have on
its outer wall a shaped formation to engage the keyway formed at
the end of the previously installed panel 17, so that the previous
panel can guide the caisson or assist in locating it. Even without
such a shaped guide formation, the abutting of the outside of eth
caisson 1 with the end of the previously installed panel 17, helps
to space and/or locate the caisson 1 while drilling occurs.
[0420] While the embodiments of FIGS. 83 and 86 show expandable
bits 4.2 and non-expandable bits 4.2', it will be understood that a
combination of expandable and non-expandable can be utilized,
providing the outer diameter of the expandable bit is equal to or
approximately equal to that of the non-expandable bit's
diameter.
[0421] The caisson or casings 1 and drilling assemblies 3 of FIGS.
83 and 86 will both produce an excavation foot print 108 as
illustrated in FIG. 88, which is sized so as to receive a pre-cast
concrete panel 17 therein, which is spaced from the earlier panel
17 on the left of FIG. 88. Once the caisson 1 is removed the space
between adjacent panels 17 can be grouted or interlocking join
piece inserted into the gap between the panels 17 to complete the
shoring wall, as described above with respect to FIG. 13 to FIG.
16.
[0422] In respect of the embodiments of FIGS. 83 and 86, a typical
outer diameter of the drill bits 4.2 when expanded or the bits 4.2'
is 290 mm, with the first centre of rotation being spaced about 15)
mm from the inside end wall of the caisson or side wall of its
opening. Whereas the spacing between centers of rotation of the
drill bits are about 208 mm apart, with the caisson 1 having an
opening, or opening footprint, of about 940 mm by 315 mm, so as to
provide an excavation footprint 108 which will receive a panel 17
of 175 mm.times.850 mm.
[0423] It will be noted that the improvement described above with
respect to FIGS. 41 and 42 can be applied to the embodiments of
FIGS. 83 and 86, in that a drilling assembly having two
appropriately spaced drill bits 4.2 or 4.2', for locating at the
first and third positions from the left of FIGS. 83 and 86 can be
provided, and so that once drilling of two holes has occurred the
drilling assembly can be removed and rotated around a vertical axis
through 180 degrees, and then the holes at the second and fourth
positions from the left drilled.
[0424] The above described embodiments relate to installing pile
elements such as a sheet, or panel or a pile wall element. The same
method and/or equipment as described above can be used, as
illustrated in FIG. 97, with a pile element such as a pile modular
wall elements 17, 17A and 17B, and their related sliding engagement
system. These can be used as a modular wall elements per se, or if
desired can be used to form an in-situ concrete formwork and panel,
and utilizes a similar method to that described above in respect of
FIG. 75 to FIG. 78, in relation to the embedment of the pile
element. Once all the pile modular walls elements 17 have been
positioned then these form a pile wall or they can have appropriate
reinforcing added and then filled by means of pumped grout,
concrete or fibre reinforced concrete, or poured gravel to create
the wall, with the formwork remaining in situ. Such modular wall
elements and pile elements 17 are described in U.S. Pat. Nos.
7,628,570 and 8,033,759 which are incorporated herein by
reference.
[0425] Thus the method of drilling and placement in respect of the
embodiment illustrated in FIG. 97 comprises a first pile modular
wall element 17 (or a series of 2 or more such elements joined
together) is positioned within the boundary 105 of the ground
disturbed or drilled by the drilling or excavation assembly 3 (not
illustrated) which also positions a caisson 107, allowing the first
pile modular wall element 17 to then be located into place in the
boundary of the series of overlapping holes 105. Then, a connecting
section or piece 125, having two rear clutches 125.11 to engage the
respective forward clutches of the first pile modular wall element
17, and forward clutches 125.2 and 125.4 to engage the clutches A
and B respectively on the caisson 107, are assembled to the
clutches A & B on the caisson 107 to which has been
pre-assembled the drilling or excavation assembly 3 (not
illustrated). The connecting section or piece 125 by means of rear
clutches 125.11 is fed into the forward clutches of the end of
first pile modular wall element(s) 17 and the forward-most first
pile modular wall element 17 will be clear of the arc of the cutter
which is digging the rear section of boundary 108, with the
assembly of drilling assembly 3, caisson 107 being guided in its
ground engagement by the forward-most first pile modular wall
element 17. When desired depth is achieved the drilling or
excavation assembly 3 (not illustrated) is removed from the caisson
107, and so too is the connecting piece 125, allowing the rear
clutches of pile modular wall element 17A to first be engaged with
the forward most clutches of element 17 allowing the element 17A to
be driven into place by either a bucket of an excavator or hammered
into place. Once the element 17A is in place, then element 17B can
be likewise installed. Alternatively elements 17A and 17B (or more)
can be pre joined, and then driven into place as a sub-assembly.
This system is then repeated until an assembly of pile modular wall
elements 17 of desired length is formed. The pile modular wall
elements 17A and 17B are represented in broken line-work as they
are not positioned until the connecting piece 125 has been removed
from engagement with the forward most end of the element 17.
[0426] During this assembly process, the lowermost end of the pile
modular wall elements 17 are held in place by means of mud or other
introduced sediment, while the upper ends are held in place by a
locating falsework or temporary support or formwork which braces
and secures the upper ends to their desired location. In such
location if desired concrete can also be poured. This locating
false work or formwork can also be used to tie in and/or form the
capping beam 28, and to tie in the interconnecting anchors 32, 32.1
and 32.2 as seen in FIG. 18.2.
[0427] While the above description of FIG. 97 indicates the use of
the connection section 125 having two rearwardly directed clutches
125.11, if desired, a modified arrangement can be utilized, such as
that illustrated in FIG. 98, where an improved TRULINE modular wall
element is extruded or formed with side located internal grooves or
clutches 17.33. By having a purpose built caisson or casing 107 for
the first wall element 17 (or assembly of elements 17) to be
inserted, and having a second purpose built caisson or casing 107
as illustrated in FIG. 98, the wall of which terminates at each end
with a respective inwardly directed clutch A and B, so as to be
located outside the diameter of the cutters, will engage the
clutches 17.33 on the, or the forward-most, wall element 17. By
this means, the caisson 107 and drilling assembly 3 (not
illustrated) can be guided in its drill process by the first wall
element 17 or assembly of wall elements 17, and once the drilling
assembly is retracted from the caisson 107, the space within the
caisson 107 is able to received elements 17A and 17B either
sequentially as single units, or as an assembly of wall elements.
The element 17A connecting to element 17 in FIG. 98, can be like
one used in FIG. 97, providing the front most element used is has
side clutches 17.33 as is the case with element 17 of FIG. 98. An
additional advantage of the grooves or internal clutches 17.33 is
that the overall appearance of the wall element 17 is substantially
unchanged.
[0428] As illustrated in FIG. 99, a wall element 17, similar in
profile to the TRULINE modular wall element, can be made having
external clutches 17.35 formed on the outside walls of the wall
element, near to one end. The embodiment of FIG. 99 will operate in
the same manner as that described with respect to FIG. 98, and like
it, the external grooves or clutches 17.35. By also having a
purpose built caisson or casing 107 for the first wall element 17
(or assembly of elements 17) to be inserted, and having a second
purpose built caisson or casing 107 as illustrated in FIG. 99, the
wall of which terminates at each end with a respective clutch A and
B, so as to be located outside the diameter of the cutters, will
engage the respective clutches 17.35 on the, or the forward-most,
wall element 17. By this means, the caisson 107 and drilling
assembly 3 (not illustrated) can be guided in its drill process by
the first wall element 17 or assembly of wall elements 17, and once
the drilling assembly is retracted from the caisson 107, the space
within the caisson 107 is able to received elements 17A and 17B,
either sequentially as single units, or simultaneously as an
assembly of wall elements. The subsequent element 17A connecting to
element 17 in FIG. 99, can be like one used in FIG. 97, providing
the front most element used has side clutches 17.35 as is the case
with element 17 of FIG. 99.
[0429] The wall elements 17 of FIGS. 97, 98 and 99 provide a
retaining wall element for use in controlling land erosion in
contact with water which has self-supporting polymeric
construction, each element having a vertical longitudinal interior
channel 17.51 disposed therein enclosed by at least three sides
17.52. If desired a fourth side can be provided and also if desired
an intermediate wall can be provided, or a fastening means to allow
an intermediate wall to be assembled thereto.
[0430] Each of the modular wall elements 17 have a pair of opposed
ends which terminate with one or more fastening means 17.53, in
this case 2 per end. Each of the modular wall elements 17 connect
to a like or similar modular wall element 17 by mating engagement
of the at least one fastening means 17.53 on one first wall element
17 with at least one fastening means 17.53 on the at least one
second wall element 17A, the fastening means 17.53 being an
engageable clutch or J-shaped hook.
[0431] The embodiments of FIGS. 98 and 99 differ from that of FIG.
97 in that at least one of the wall elements includes in or on at
least one of a front wall 17.54 and/or rear wall 17.55, an
elongated fastening means 17.33, 17,35 allowing the at least one
wall element to connect to the ends A and B of a wall or walls of a
casing or caisson 107 and/or a drilling element 3, which will be
used to drill and/or keep clear a volume in which the element 17 or
17A or elements 17 and 17A will be installed in an underwater
location.
[0432] The fastening means 17.35 on the front wall 17.54 and/or the
rear wall 17.55 are illustrated in FIG. 99 as being an externally
arranged engageable clutch or J-shaped hook; whereas in FIG. 98 the
fastening means 17.33 are illustrated as being an internally
arranged engageable clutch or groove able to receive a J-shaped
hook.
[0433] The wall elements 17, 17A 17B of FIGS. 97, 98 or 99 are
formed or constructed, by virtue of its wall formation, features,
shape and/or thickness, to function as a structural wall when it is
in a hollow condition.
[0434] Additionally, wall elements 17, 17A 17B of FIGS. 97, 98 or
99 are initially hollow and when joined and assembled with like or
similar elements, are then used as an in-situ formwork and
subsequently filled with concrete, cement or grout to form a
finished structural wall construction.
[0435] If three walls 17.52 are present on each element 17, 17A or
17B, then at least one end cap having a fastening means to attach
to the element can be used so as to close off the otherwise open
volume of the end section of the element.
[0436] Illustrated in FIGS. 100 to 109 is a combination drilling
and reaming tool 3 for direct use with the wall elements 17, 17A
and 17B of FIGS. 97 to 99, that is where a caisson or casing 107 is
not unlisted.
[0437] Illustrated in FIG. 100 is a modular wall element 17A
engaging a like modular wall element 17, each being such as a
TRULINE modular wall element, into which is positioned a drilling
and/or reaming assembly 3 which has a rotating non-expandable drill
bit 4 which is at the base of a drive shaft 6. At a location above
the drill bit 4 is a pair of reaming elements 3.1 (on opposite ends
of a cable or such like) which is shown as being bent in FIG. 100,
so that its ends 3.11 are downwardly directed while the assembly 3
is exiting the wall element 17A as the drill assembly 3 is pulled
through after drilling and reaming has been completed. The pairs of
reaming elements 3.1, (or multiple pairs of elements as there can
be a multiple pairs of the reaming elements 3.1 at different
heights on the shaft 6 as described in more detail below) can also
have their ends 3.11 upwardly directed as the drilling assembly 3
is pushed through the wall element 17A. Before being inserted into
the water, on a land location near to the installation site, whilst
still laid flat onto ground, a drilling assembly 3 and a modular
wall element are assembled together so that the one or more pairs
of reaming elements 3.1 and drill bit 4 are situated proud of the
lower rim 17.33. It is in this state that they are locked together
by a pin or other mechanical releasable interconnecting means. When
so locked together, they can be hoisted together, with the lowest
point of the clutches 17.53 being engaged with the clutches of the
earlier installed wall element 17, and then pushed down until the
drill bit engages ground to be drilled and/or reamed. When drilling
and/or reaming is complete, and the wall element 17A is at a
desired depth, the releasable mechanical interconnection is
released, and the clutches of the interconnnected elements 17 and
17A can then be locked together preventing their separation, and at
this point, the drilling and reaming assembly 3 can be withdrawn
from the wall element 17A.
[0438] The respective pairs of reaming elements 3.1 will have their
maximum length or diameter when rotating, determined by the
geometry as depicted in FIG. 112, and this will be described in
detail below. The reaming elements 3.1 or pairs of reaming elements
3.1 are preferably made from helically wound stranded cables of
mild steel of approximately 10 mm to 50 mm in outside cable
diameter, with the preferred being of the order of 20 mm. It will
be understood that this dimension will need to be a compromise
between the amount of flexibility required of the reaming elements
3.1 as it is pulled through the wall element 17A after completion
of the drilling and reaming process, as well as other factors such
as the size of the wall element 17A, compared to the power
available to rotate the drilling and/or reaming assembly 3, and
even the pressure of pumping of the drilling fluid.
[0439] The helically wound spiral strands at the respective ends
3.11 are welded together to prevent the individual strands from
unravelling from the cable during reaming operations. The outside
shape of the cable, being "shaped" or "profiled" due to the
helically wound nature of the cable, acts like a series of radially
located teeth, which will engage the ground surface to be reamed,
when the drilling assembly is rotated at the order of 50 to 70 RPM,
or a higher or lower speeds depending upon the hardness of the
ground which the reaming tool 3.1 is to engage. The drilling bit 4
can be an expanding bit but its size is determined solely on its
ability to move into and out through the modular wall element 17.
When the drill bit 4 is engaging the ground to be drilled and
reamed, its main role is to guide the reaming elements 3.1 in their
downward journey. As will be described later, the drill and reaming
assembly 3, is guided in its motion downward, by the modular wall
element 17A, which will downwardly slide along the clutch of an
earlier positioned like modular wall element 17.
[0440] As illustrated in FIGS. 102 and 103, which are underneath
views of the arrangements of FIGS. 100 and 101 respectively, the
reaming tool 3.1 shows the ends 3.11 as being multi-stranded, and
each strand is in itself a multi-stranded cable element. When the
ends 3.11 are free of the confines of the modular wall element 17A,
they expand to their full length, or at least will do so, when
rotated by the drive shaft 6 at 50 RPM to 70 RPM.
[0441] The reaming elements 3.1 can be considered to make up a
single tool called a reaming bit having four or six expanding
parts, depending on how many cable or spring steel sections are
utilized.
[0442] From FIGS. 102, 103 and 112, it will be noted that the drill
bit 4 and pairs of reaming elements 3.1 have their centre of
rotation 4.15, being also the centre of rotation of the drive shaft
6, is located off-centre relative to the length of the modular wall
element 17A, as best exemplified by the dimension OD1 in FIG. 112,
which shows the offset from the physical centre of the overall
length of the element 17A, or the dimension OD2 which shows the
offset from the structural centre of the wall element 17A. From
FIG. 103 it will be noted that the extremities of ends 3.11 when
rotated around the axis 4.15 extend past the free clutches 17.53 at
the forward-most end of the modular wall element 17A being
illustrated by distances F1 and F2, but also will not intersect or
collide with the clutches 17.53 on the modular wall element 17
already or earlier positioned into the ground, by distances C1 and
C2 and which clutches 17.53 act as a guide for the modular wall
element 17A being inserted and thus the drilling and reaming
assembly 3. It is possible that the off-set distances OD1 and OD2
are in fact the same dimension, as a scale representation of the
modular wall element 17A is not provided in this document.
[0443] To achieve this off-centre arrangement, the dimensions F1,
F2, C1, C2 and S1 and S2 will be of the order of 5 mm to 20 mm and
will be dependent upon several factors including the tolerances in
the drill string, the type of ground being drilled, which may cause
the bit to wander off line. Once the drill centre is identified,
then one or more guide plates 3.23 are utilized along the length of
the modular wall element 17A, so as to locate and keep the centre
of rotation 4.15 of the drill bit 4, reaming tool 3.1 and the drive
shaft 6 at the correct positional arrangement to prevent the
collision of the reaming tool 3.1 with the clutches of the earlier
positioned modular wall element 17, and yet to excavate ahead of
the clutches 17.53 at the forward-most end of the modular wall
element 17A being positioned or inserted. This is best illustrated
in FIG. 112, where a single drilling and reaming tool assembly 3,
having one centre of rotation 4.15, will excavate a cylindrical
excavation 108, which will overlap with the previously formed
excavation 105, but which will not overlap with the forward-most
point of the forward clutches 17.53 of the earlier positioned
modular wall element 17. As the reaming tool is below the lower rim
17.33 of modular wall element 17A, there will be no interference
from the rear end clutches of modular wall element 17A which engage
clutches 17.53 of modular wall element 17 positioned earlier.
[0444] The guide plates 3.23 are shaped so as to provide a good
sliding fit with the internal shape of the modular wall element
17A, and there is preferably approximately 2 mm to 5 mm of
clearance between the outside surface of the guide plate 3.23 and
the internal surfaces of the modular wall element 17A. Thus as
illustrated in FIG. 109, the end 3.231 is shaped so that the
clutches and formations provided will not interfere with the
sliding movement (or vica-versa), and at an intermediate location
grooves 3.232 are provided to accommodate the T-shaped joining
formations on at the centre of the modular wall element 17A. As
illustrated in FIG. 108, the guide plate 3.23 includes a
cylindrical journal bearing 3.233 to assist the drive shaft 6 in
its rotation. The lower guide plate 3.23 has an upwardly extending
portion 3.234 which extends upwardly for optional connection to a
similarly constructed intermediate guide plate, and so on up
through the modular wall element 17A, until the upper end is
reached at which upper end the drill motor 3.20 is mounted. The
number of guide plates 3.23 will be dependent upon the length of
the modular wall element 17A.
[0445] As an alternative to the provision of guide plates 3.23, the
drilling and reaming assembly 3 can be preassembled, as illustrated
in FIGS. 114 and 115 into a housing arrangement which sits within
and slides within the wall element 17A. The housing arrangement or
mandrel as illustrated can be either of a solid construction or of
a hollow construction. The mandrel has a shaped body 3.13, which
has a similar outer peripheral shape, as best illustrated in FIG.
115, to that of the guide plates 3.23, whereby a sliding fit into
the modular wall element 17A will result. The drilling and reaming
assembly 3 of FIGS. 114 and 115 has a motor 3.20 below which is
mounted a drilling fluid or water swivel 3.241 to which connects
the flushing line 3.24. Below the swivel 3.241 is the drive holder
3.21 which will fit over the upper rim of the modular wall element
17A, and which can be releasably locked together by a pin or a bolt
or any appropriate means, once the mandrel body 3.13 is inserted
within a wall element 17A.
[0446] Like drilling and reaming assembly 3 of FIGS. 100 to 109,
the drilling and reaming assembly 3 as best illustrated in FIG.
115, the assembly 3 has a drive shaft 6 which extends from the
motor 3.20 to the drilling bit 4 and reaming bits 3.1, as well as a
horizontal flushing fluid outlet port 6.2 when the assembly 3 is
vertical, or which can be described as ejecting flushing fluid at
an angle of approximately 90 degrees to the longitudinal axis of
the drive shaft 6.
[0447] Additionally, as shown in cross section in FIG. 115, the
shaped body 3.13 like the guide 3.23, have their respective ends
3.231 being similarly shaped, so as to be slidably received by the
wall element 17A, when inserted into the element 17 and be clear of
the wall formations and clutches. The difference between guide 3.23
and body 3.13 is that the end 3.231 of the body 3.13 extends the
full length of the body as best illustrated in FIG. 114. Similarly,
the location groove 3.232 on the opposed sides of the body 3.13
extend the full length of the body 3.13 and are shaped similarly to
the grooves 3.232 of the guides 3.23, so as to be slidably received
by the intermediate T-shaped joining formations of the wall
elements 17A. Also like the guide 3.23, the body 3.13 is sized so
that there exists approximately 2 mm to 5 mm of clearance between
the outside surface of the body 3.13 and the internal surfaces of
the modular wall element 17A or 17.
[0448] As illustrated in FIGS. 114 and 115 the drilling and reaming
assembly 3 has two pairs of reaming elements 3.1 which can be held
in "bits" in the drive shaft 6, or as part of separate bits which
are added to the base of the drive shaft and to which the drill bit
4 is also attached. The respective two pairs of reaming elements
3.1 are formed from a spiral wound cable as described above or they
can be made of spring steel bar or formed with parts constructed of
cable or spring steel, to clear an excavation 108, as in the
earlier embodiment. Like the earlier embodiments, there can be only
a single pair of reaming elements 3.1, which will provide the most
dynamically stable arrangement, or if desired there could be only a
single reaming element (not a pair of) being only a single arm
extending in one direction only from the drive shaft 6.
Alternatively there can be more than two opposed pairs, or more
than one single arm reaming element, located at different heights
on the drive shaft 6, and also being angularly spaced from the
adjacent single arm reaming elements.
[0449] The drilling and reaming assembly 3 of FIGS. 114 and 115, is
preferably of a length to suit the length of the wall element 17A.
However, if desired the body 3.13 can be made in multiple joinable
segments or parts so that segments of the body 3.13 can be
removable or receive more like segments to increase or decrease the
length of the body 3.13 and the dive shaft 6.
[0450] As is illustrated in FIGS. 104 and 105, the drilling and
reaming assembly 3 has a motor 3.20 such a hydraulic motor or the
like. A flushing line 3.24 connects via a rotating joint (not
illustrated- see item 3.241 in FIG. 114 for a similar rotating
joint) with the drive shaft 6 longitudinally extending flushing
hole 6.1, which as is visible in FIG. 106, descends down to the
base of the shaft 6 and through the drill bit 4, so as to provide
horizontally directed flushing streams 6.3, from horizontal
passages 6.2 at the base of the drive shaft 6 or in the drill head
4. The preference is that the drilling fluid or flushing medium
utilized exits the drill assembly 3 at the lowermost point, and as
such this will be horizontally through the drilling head 4. This
will ensure delivery of the fluid material direct to the
undisturbed portion of the area being excavated. The flushing
system formed with drill fluid delivery line 3.24-not shown
connected) can be used to pump water, mud, air, polymer
compositions, bentonite or any other appropriate flushing or
drilling compound, as will be known to those skilled in the art.
Preferably the flushing system will be pressurized to of the order
of 50 to 500 PSI.
[0451] Preferably the section of the drilling and reaming assembly
3, between the drive holder 3.21 and the lower guide plate 3.23, is
of a modular construction, so that "modules" of drilling and
reaming sections can be added/assembled or removed/disassembled
from the assembly 3, so that different lengths of modular wall
elements 17A can be positioned. This modular nature of the drilling
and reaming assembly 3 can be achieved by screw thread connections
between the modular components.
[0452] The upper end of the assembly 3, below the motor 3.20
includes a drive holder 3.21 which has an undercut channel portion
3.22 into which can be receive the upper rim of the modular wall
element 17A to be inserted. The combined action of gravity active
upon the upper rim of modular wall element 17A, and the drilling
and reaming action of the drilling and reaming assembly 3, ensures
that the modular wall element 17A will descend to the desired depth
into the ground being drilled and reamed. It is not expected that
the drive holder 3.21 will have to transmit percussion and/or
vibratory force to the wall element 17A, but it can be configured
so as to be readily adapted to do so.
[0453] The above description has the reaming elements 3.1 being
made exclusively from sections of cable. However if desired, the
reaming elements 3.1 need only have a cable section at the location
where bending is to be present. Thus the reaming tool 4.1 need only
need be partially made from a cable. Additionally, the reaming
element 3.1 could be made as a spring steel reaming element or have
a spring steel portion, to provide the flexibility and resilience
needed to draw the reaming elements 3.1 out through the wall
element 17A once reaming and drilling is completed.
[0454] Another alternative is that the reaming elements 3.1 can be
made as an expanding and contracting reaming bit, whereby through
an arrangement of levers and mechanisms, the reaming bit can be
contracted for withdrawal purposes. Additionally or alternatively,
the reaming elements 3.1 can be of the sort that expand by rotation
or otherwise can be hydraulically activated.
[0455] As best illustrated in FIG. 104, the reaming elements 3.1
can be made up of a multiple of reaming elements 3.1, 3.1A, 3.1B
and 3.1C, so that they are radially spaced on the drive shaft 6, as
best illustrated in FIG. 107, at approximately 45 degrees apart in
plan view. Preferably the helically wound cable elements which form
the reaming elements 3.1, are held immoveable and centred relative
to the drive shaft 6 by means of a grub screw or bolt which engages
the cable at 90 degrees, and secures it into place. This allows
ready replacement of worn cable elements 3.1. If ready replacement
is not required, then the elements 3.1 can be welded or crimped
into place on the drill shaft.
[0456] The cable length which forms the elements 3.1 ensures that
there is sufficient flexibility and resilience, so that the ends
3.11 will bend and fit into the cavity of the modular wall element
17A, when the drill and/or reaming assembly 3 is being inserted
into and/or withdrawn from the modular wall element 17A. In the
region of the section of drive shaft 6 where the reaming elements
3.1 to 3.1C are located, the internal passages which will carry the
drilling fluid have a greater cross sectional area than the reaming
tool diameter so that when they intersect and the cable installed,
there is a path for drilling fluid under pressure to pass around
the cable and continue on to the horizontal outlets.
[0457] The length of the cable section selected for the pairs of
reaming elements 3.1 is based on the location of the centre or axis
of rotation of the drilling and reaming bits being at an off-centre
location, as best illustrated in FIG. 112, where the extremities of
the drilling and/or reaming bits have a locus or rotation envelope
or excavation which clears the clutches 17.53 of a previously
installed modular wall element 17, and which locus or rotation
envelope or excavation extends past the forward or opposite side
clutches 17.53 of the wall element 17A being installed.
[0458] It will be understood that the very first wall element, for
example modular wall element 17, will be installed by the same
drill assembly as used by the second wall element 17A, except that
the reaming bit will have longer cable sections for the pairs of
reaming elements 3.1, so that from the centre of rotation or
rotation axis, the extremities of the ends 3.11, when fully
extended will have a locus, or rotation envelope, or excavation
footprint, which clears the forward and rearward clutches 17.53 of
the modular wall element 17 being first installed. It is for this
reason that having the cable or tool holder being for example a
grub screw can be highly advantageous as multiple drilling and
reaming assemblies 3 is not required.
[0459] FIGS. 100 to 109 and 112, illustrate a wall element system
and drilling and/or reaming assembly 3 which has a single drilling
and reaming drive shaft 6 and rotation axis 4.15. Illustrated in
FIGS. 110 and 111, are the geometries to achieve a similar result
as that illustrated in FIGS. 100 to 109 and 112, but with two
rotation centers, where the drilling and reaming assembly 3 has two
drive shafts 6, with bit 4 and reaming tools 3.1 on one shaft and
located at a different height to the other shaft.
[0460] While the drilling and/or reaming assemblies 3 of FIGS. 100
to 115 have a motor 3.20 located outside of the wall element 17A,
it will be readily understood that the motor 3.20 can be located
inside the wall element 17A, but must be of a size that allows for
the extraction of the motor and drilling and/or reaming bits
through the wall element 17A. Additionally the motor can be at an
upper location within the wall element 17A, or at an intermediate
location or at a lower location within the wall element 17A.
Further the motor 3.20 could be located below the wall element 17A,
but this is expected to require the drilling and/or reaming of
deeper excavations, than that expected with the other locations
described above.
[0461] Illustrated in FIG. 113 is a caisson or casing system,
similar to that of FIG. 97, which utilizes a connection piece 125
which does not engage the clutches 17.53 on the first positioned
wall element 17. Instead the connection piece 125, which is
removeable from the caisson or casing 107, due to rearward
extensions 125.3 will prevent the caisson or casing 107 from moving
in a direction up or down the page as illustrated in FIG. 113, and
by the exertion of a relatively small force in the direction from
the caisson or casing 107 towards the wall element 17, the caisson
or casing, by means of the outside face of the connection piece 125
sliding over the outer points of the clutches 17.53, will be able
to achieve a sufficient guiding action of the drilling or drilling
and reaming assembly 3 to sink the caisson or casing 107 into and
overlapping excavation 108 into the ground.
VI. LEGENDS
[0462] FIGS. 1.1, 1.2, 1.3, 2.1, 2.2, 2.3, 3.1, 3.2, 3.3, 4.1, 4.2,
4.3, 5 to 10, and 13 to 22 have the following feature legend (not
all are listed): [0463] 1--caisson; [0464] 1.2--structural core
cast inside a caisson to be left in situ; [0465] 2--caisson leading
edge; [0466] 2.1--gap between caisson/casing and the body of the
drilling assembly; [0467] 3--excavation drilling assembly; [0468]
4--drill bit retracted; [0469] 4.1--drill bit extended or expanded;
[0470] 4.2--drill bit extended or expanded; [0471] 4.3--drill bit
extended or expanded; [0472] 5--rotation motor; [0473] 6--drive
shaft; [0474] 7--hydraulic flow divider; [0475] 8--bearing housing
with flushing hole; [0476] 9--base of bearing with flushing hole;
[0477] 10--latch assembly; [0478] 10.1--latch body; [0479]
10.2--latch pivot stationary relative to drill assembly 3; [0480]
10.3--latch pivot moveably pivoted and mounted to lift flange 12.1;
[0481] 10.4--mounting plate attached to drill assembly 3; [0482]
11--recess in caisson to accept latch; [0483] 12--lifting assembly
or chain; [0484] 12.1--lifting flange or eye; [0485]
12.2--compression spring; [0486] 12.3--mounting bolt; [0487]
12.4--mounting washer; [0488] 12.5--mounting nut; [0489]
13--hydraulic hoses; [0490] 14--flushing hoses; [0491] 15--flushing
hole in drill bit; [0492] 16--normal direction of rotation to keep
retracted; [0493] 17--structural panels; [0494] 17.1--vertical gap
between adjacent panels; [0495] 17.2--pre-existing structural panel
in the ground; [0496] 18--stocking; [0497] 19--grout line; [0498]
20--grout key; [0499] 21--grout tube for toe grouting; [0500]
22--toe grout; [0501] 23--penetration for dowel; [0502] 24--hard
ground or rock; [0503] 25--hole drilled into hard ground or rock;
[0504] 26--dowel; [0505] 27--grout line for down penetration hole;
[0506] 28--capping beam; [0507] 28.2--existing capping beam; [0508]
29--apertures for capping beam reinforcement bars; [0509]
30--reinforcement bars inserted into apertures in the panel; [0510]
31--reinforcement bars cast into the panel; [0511] 32--anchoring
ties; [0512] 32.1--extended portion of an anchoring tie linking new
and existing capping beams; [0513] 32.2--anchoring tie to an
existing capping beam; [0514] 1'--trailing caisson; [0515]
33--displaced plasticized ground matter; [0516] 34--trailing edge
projection for end-to-end attachment between caissons; [0517]
35--leading edge projection for end-to-end attachment between
caissons; [0518] 36--groove in the leading edge projection to
accommodate the trailing edge projection of an adjacent caisson;
[0519] 38--rope used in a pulling operation to lower the caisson;
[0520] 40--pulley used in a pulling operation to lower the caisson;
[0521] S--parting plane between sections of a caisson; [0522]
100--hydraulic or pneumatic cylinder.
[0523] FIGS. 23 to 50 include features from following legend (not
all are listed): [0524] 101--first sheet to be placed; [0525]
102--second sheet to be placed; [0526] 103--third sheet to be
placed; [0527] 104--clutch; [0528] 105--boundary of the ground
disturbed while placing the first sheet; [0529] 106--connecting
section of the caisson; [0530] 107--caisson; [0531] 108--boundary
of the ground disturbed by the tool or excavation footprint; [0532]
109--expandable drills; [0533] 110--tool holding the expandable
drills; [0534] 111--blank connecting piece; [0535] 112--sheet to be
connected too; [0536] 113--last full sheet placed; [0537]
114--fabricated connecting piece; [0538] 115--boundary of the
ground disturbed placing sheet 112; [0539] 116--boundary of the
ground disturbed placing sheet 113; [0540] 117--layer of hard
ground the sheet pile must pass through; [0541] 118--ground level;
[0542] 119--hard seabed; [0543] 120--water level; [0544] 121--soft
seabed; [0545] 122--grout filling the drilled hole; [0546]
124--caisson half; [0547] 125--connecting section or piece; [0548]
126--connecting pin/bolt; [0549] 133--expanding drill in retracted
condition; [0550] 134--expanded diameter being drilled; [0551]
135--adjacent diameter to be drilled next; [0552] 136--holes
previously drilled; [0553] 137--hydraulic motor for powering drill;
[0554] 138--ground level; [0555] 139--conventional sheet pile
driving implement or equipment; [0556] 140--cast locating groove;
[0557] XX--axis in plan through the clutches of the sheets to be
installed; [0558] YY--minor axis in plan through the caisson 107
and the tool 3.
[0559] Where ever it is used, the word "comprising" is to be
understood in its "open" sense, that is, in the sense of
"including", and thus not limited to its "closed" sense, that is
the sense of "consisting only of". A corresponding meaning is to be
attributed to the corresponding words "comprise", "comprised" and
"comprises" where they appear.
[0560] It will be understood that the invention disclosed and
defined herein extends to all alternative combinations of two or
more of the individual features mentioned or evident from the text.
All of these different combinations constitute various alternative
aspects of the invention.
[0561] While particular embodiments of this invention have been
described, it will be evident to those skilled in the art that the
present invention may be embodied in other specific forms without
departing from the essential characteristics thereof. The present
embodiments and examples are therefore to be considered in all
respects as illustrative and not restrictive, and all modifications
which would be obvious to those skilled in the art are therefore
intended to be embraced therein.
* * * * *