RAPID MOULDING OF HOLLOW ELONGATE CONCRETE ARTICLES

Abstract: Apparatus for and a method of casting annular concrete articles such as poles or pipes. The apparatus and method comprises establishing a suitable mould (10), defining the desired mould cavity or shape (13) into which wet or uncured concrete is introduced. Thereafter excess water is removed from the concrete by pressing at least a movable internal wall (66) of the mould against the concrete within the mould cavity to pass water therefrom through drainage means (19, 20) associated with the movable internal wall to thereby provide a moulded concrete article having the characteristics of at least a partly cured concrete article whereby the mould can be removed from the article for reuse.

Description: RAPID MOULDING OF HOLLOW ELONGATE CONCRETE ARTICLES The present invention relates to method and apparatus for making concrete pipes or poles particularly reinforced concrete pipes or poles. In my earlier Australian Patent Application No. 27199/84 there is disclosed a process and apparatus for forming an elongate concrete moulded article from high slump concrete wherein surplus liquid is removed through a porous membrane extending around the outer perimeter of the article when the membrane is arranged to provide compression to the concrete within the mould and thereafter separating the membrane from the surface of the partially dried concrete and removing the article from the mould without significiant damage to the cast concrete article. This enables almost immediate reuse of the mould. A disadvantage of this method is that the external periphery of the concrete article, although visually undamaged, is not smooth. Furthermore, the process disclosed therein cannot be easily utilised by application of a membrane to the internal periphery of the article. The present invention seeks to overcome this problem yet provide a rapid drying process for concrete articles made from concrete having high slump characteristics leaving an acceptable external surface finish particularly suitable for use on street poles. It will of course be appreciated that either poles or pipes might be manufactured by the present process and apparatus. There is provided according to the present invention a process for forming an elongate moulded article made from a settable material such as concrete comprising the steps of forming a mould defining an inner and an outer surface corresponding to opposed surfaces of the moulded article formed therein, said mould being arranged whereby at least said inner surface is movable relative to said outer surface; filling said mould with the settable material. compressing the settable material by movement of at least said inner surface relatively towards said outer surface to remove surplus liquid from said settable material such that the settable material is given the, characteristic of being at least partially cured, and thereafter moving said inner surface relatively away from said outer surface ' to release said article from the mould and separating the mould from the said article. Conveniently, the inner and the outer surfaces of said mould are arranged to form an elongated annular mould cavity there between whereby a pipe or pole may be formed thereby. In such a case the inner surface is arranged to move radially towards and away from said outer surface. In some cases practical problems may be encountered in removing excess moisture from the outer surface of the moulded article. If the excess moisture is not removed, it may cause difficulties in achieving a smooth outer finish on the article even with careful peeling of the mould therefrom. In the light of this, it is particularly preferred to provide means associated with the outer surface of the mould to remove any excess moisture from the outer surface of the moulded article. Conveniently this may be achieved by, at least during part of the process, applying pressure to both inner and outer surfaces of the moulded article to cause migration of residual water from the said inner and outer surfaces of the moulded article. Alternatively or in addition to said process step, the outer mould surface may be provided with an absorbent material layer adapted to absorb surface moisture from the moulded article prior to separating the mould therefrom. In accordance with a further aspect of the present invention, there is provided a moulding apparatus for producing an annular elongate article from a settable material such as concrete, said apparatus comprising an outer mould construction defining an inwardly facing mould surface adapted to form an outer surface of the article moulded therein, an inner mould construction adapted for location within said outer mould construction and defining an outwardly facing mould surface adapted to form an inner surface of the article moulded therein, said inner and outer ' mould constructions defining an elongated annular mould cavity, said inner mould construction further including means for moving said inwardly facing mould surface radially towards said outer mould construction and moisture transference means associated with said outwardly facing mould surface to pass moisture formed on the inner surface of the article moulded therein away from said inner surface when the settable material within the mould cavity is compressed by relative movement between said outwardly and said inwardly facing mould surfaces, and said apparatus further including means for introducing said settable material within said mould cavity. .The outer mould construction is preferably formed in two halves, each half being covered with a resilient membrane to form a smooth outer surface on the moulded article. The resilient membrane may be constructed in a manner whereby it can be peeled away from the surface to minimise surface damage. The invention will be described in greater detail having reference to preferred embodiments illustrated in the accompanying drawings, in which : Figure 1 is a schematic sectional view of a general mould assembly with some parts omitted; Figures 2 and 3 are partial longitudinal and transverse sections through the mould assembly of figure 1; Figure 4 is a partial enlargement sectional view of the bottom of the outwardly facing inner mould surface of figure 1; Figure 5 is a schematic transverse sectional view of the inner and outer mould constructions taken along lines v-V of figure 1; Figure 6 is a partial longitudinal sectional view of an alternative embodiment to that shown in figures 1 to 5 taken along line VI-VI of figure 7; Figure 7 is a partial transverse sectional view taken along line VII-VII of figure 6; and Figures 8(a) to 8(d) are schematic process diagrams applicable to the embodiments of both figures 1 to 5 and 6 to 7. With reference to Figures 1 and 5, an outer mould construction 10, is shown formed in two semi-cylindrical halves 60,61, closed around an inner mould construction 3. The outer mould halves 60,61 include flanges 4 which may be bolted to the flanges of the other outer mould half or preferably releasably held with hydraulic clamping jacks (not shown) . A reinforcing cage 2 of known construction is • positioned concentrically within an annular space 13 formed between the two mould constructions 3,10. A lower mould closing body 63 is provided with concrete feed inlet 12 communicating with a chamber 6 for receiving pumped concrete and for introducing said concrete into the annular mould cavity 13. A drainage extension member 7 permits the egress of liquid from the mould assembly and also serves to locate the inner mould 3. The concrete used is preferably high slump (or very wet) in consistancy and the pumping pressure is such as to force the concrete from the bottom up into top of the mould cavity 13. It will of course be appreciated that alternative concrete introduction methods may be employed. For example a suitably shaped tremmie may be introduced into the mould cavity 13 from one end to a position adjacent the other end and thereafter progressively withdrawn while introducing high slump concrete into the cavity. Figures 2 and 3 show partial sectional views of the inner and outer mould constructions 3,10. The outer mould construction 10 includes a substantially rigid supporting outer shell 65 and an inner liner construction 64. As seen in figures 2 and 3 the liner construction 64 is preferably comprised of an inner impervious resilient rubber or plastics material membrane 11 and a porous or permeable membrane 26 located between the inner membrane 11 and the outer shell 65. The membrane 11 preferably has a smooth inwardly facing surface defining the outer mould surface and may be arranged continuous over the inner surfaces of the outer mould halves 60,61. The inner mould construction 3 is more complex in nature because it is adapted to provide compression against the inside surface, of wet concrete located in the mould cavity 13 and to ensure adequate clearance permitting insertion and removal of the inner mould without fouling other mould assembly components or the moulded article itself. The inner mould construction includes a substantially rigid supporting inner former 17 and inner moveable wall construction 66 having an outwardly facing inner mould surface adapted to contact the concrete located in the mould cavity 13. The wall construction 66 includes inflatable longitudinal tubes 14 extending the length of the mould assembly, metal sheathes 15 and at least one circumferential biasing band 23 of elastic material. An inner impervious membrane 18 is mounted top to bottom of the mould and at regular intervals around the inner membrane 18 there are longitudinally extending filters 19 and moisture drainage galleries 20. As is apparent in figures 1 to 3, a series of openings 9 are provided extending through the outer mould shell 65 and are adapted for connection to either a source of pressurized air or a source of vacuum whereby pressure is applied to the liner construction 64 to force same inwardly or to draw the liner construction against the inner contour of the shell 65 for reasons explained hereinafter. This movement of the liner construction 64 is achieved because its longitudinal edges and peripheral top and bottom edges are bonded or otherwise secured in a substantially gas tight manner to the outer shell halves 60,61. Similarly means (not shown) are provided to connect the inner regions of longitudinally directed tubes 14 and separately the circumferential spaces 83 between the inner impervious membrane 18 and the inner forme ' r 17 outwardly of the tubes 14 with either pressurized air or vacuum. This is diagramatically shown by arrows 84 and openings 85 shown in figure 1 and the reason for this capability will also be explained hereinafter. As best illustrated in figures 1 and 4, any liquid transferred from the concrete after introduction to the mould cavity enters the drainage galleries 20 through filters 19 and passes downwardly to the base of the mould assembly where it is deposited into an annular drainage chamber 21 (figure 4). Figure 4 of the drawings illustrates, in partial section, the lower end of the inner mould construction 3. The centre line of this mould assembly is represented by numeral 42 and the non-illustrated half of the construction is an identical mirror image to that portion illustrated in figure 4. It will be seen that the lower ends 28 of each of the longitudinal tubes 14 are sandwiched between and closed (or flattened) by an annular wedge element 71 and an abutment 72 on the drainage extension member 7. An O-ring sealing member 30 prevents the escape of any significant pressure from either the tubes 14 or the annular space surrounding the tubes. The wedge element 71 is forced upwardly against the tube ends 28 by tightening a nut and screw connection 29. The annular drainage collection chamber 21 is formed by an annular member 73 surrounding the member 7. A nut 74 is screwed into the member 7 and forces the upwardly divergent free edge of the member 73 against the membrane assembly 18, 19 and 20. In this manner, the collection chamber 21 is formed between the element 73 and the member 7 into which the lower ends of the drainage galleries 20 extend. Thus excess liquid may drain from the galleries 20 via the chamber 21 and outwardly of the mould assembly through passage 8. A brief description of the method of operation of this mould assembly will hereinafter be made with reference to figure 8. At the start of the moulding process the inner mould construction 3 is in a withdrawn or .raised position above the outer mould construction 10 and the two outer mould halves 60,61 are separated from each other. The inner mould construction 3 is then lowered into position inside and concentric to a suitably placed reinforcing cage 2 of conventional design. If one uses a tremmie for the introduction of concrete into the mould cavity, it is preferred that the tremmie be lowered simultaneously with or prior to positioning of the inner mould construction 3. The outer mould halves 60,61 are then positioned around the cage 2. The base 63 and the upper section (not shown in figure 8) for connecting regions of the mould to pressurized air or vacuum are then moved to close the upper and lower ends of the mould assembly. A partial vacuum may at any suitable stage be introduced through the holes 9 in mould wall 65 to ensure that the flexible membrane 11 conforms to the inner shape of the mould wall 65. With the outer mould halves 60,61 in a closed condition forming a concrete-tight joint at adjoining longitudinal flanges 4 and the base section 63 appropriately fitted to the bottom end of mould halves, air pressure (or other pressurized gas) is then applied to the inside of the collapsible tubes 14 to expand the sliding steel formers 15 as shown in Figure 3. In this manner a rigid form of predetermined diameter is achieved by the expansion of the forms 15 by the tubes 14. The pressure within the tubes should be sufficient to withstand the pressure of pumping of concrete into the cavity 13 and may be over 100 psi. High slump (very wet) concrete is then pumped through the concrete feed inlet 12 of the base section 63 through the chamber 6 and into the mould cavity 13 until mould cavity is full. Air may be vented from the mould cavity through a hole in the top mould construction 10. Alternatively, if a tremmie is used concrete may be introduced at a much lower pumping .pressure or possibly even arranged to gravitate into the mould cavity 13. During introduction of concrete into the cavity 13, pressure is maintained in the tubes 14 to maintain the outer surface of membrane 18 at the desired predetermined diameter. When the mould cavity 13 is full and the mould assembly closed, pressure may then be introduced to the space 83 between the longitudinally extending tubes 14 and thereby to the expandable membrane 18 which is thereby pressed against the concrete in the cavity 13. Fitted to the membrane 18 at spaced locations therearound are the filter membranes 19 covering drainage galleries 20. These filter membranes 19 are also pressed against the concrete causing excess water in the mix to pass through the membrane 19 and into a drainage gallery 20 between the filter membrane 19 and the rubber membrane 18. The filters 19 and drainage galleries 20 are fastened in position around membrane 18 by fastening strips 31. The water passes downwardly along each of the galleries 20 into the annular space 21 (best seen in Figure 4) and out to atmosphere through hole 8 in the drainage stem 7. Vibration may be applied if desired to the outer mould construction 10 to assist with the removal of water and the compaction of the concrete. As discussed earlier in this specification, one possible problem which may arise in the practice of the present invention lies with the possibility of excess moisture levels appearing at the outer surface of the moulded article. In a preferred embodiment, to solve this problem should it occur, the process of this invention is further modified in that when compression of the concrete is at or near maximum pressure as applied by the inner mould, pressure is then applied to the outer impervious membrane 11 to move substantially all excess surface moisture from the outer surface of the concrete toward the inner surface to thereby substantially dry the outer surface of the concrete. Pressure may be applied to membrane 11 to effect this .inwardly directed pressure on the outer surface of the concrete. The pressure being applied through apertures 9 while pressure is also maintained on the inner concrete surface by the inner mould 3. In a further preferred aspect of the invention the impervious membrane 11 may be replaced by a laminate of compressible water absorbent material such that during compression of the concrete, moisture is removed from the concrete and upon removal of compression forces excess water is absorbed by said absorbent material. With reference to the abovementioned absorbent modification, there may be attached to the membrane 11 (Figures 1 to 3) a thin layer say 1mm. thick of a compressible absorbent cloth such as chamois or synthetic chamois. Laminated or otherwise attached to the cloth may be a layer of permeable nylon material or the like- similar to the permeable filter layer 19. Both layers would be permeable to water and would function as follows:- The layer of nylon forms the liner for the moulded concrete and water is able to pass freely through it into the absorbent compressible cloth layer. When the mould is filled with concrete and pressure.is applied as described by membrane 18 the cloth layer is compressed and will not take up any significant amount of water such that water is passed back into the concrete and out through the membrane 19 as described. When the concrete is ready to be stripped the outer mould 10 is moved radially out and the cloth layer expands to enable absorption of excess moisture at the concrete surface. This method will remove all excess water from the concrete surface effectively, however, it suffers from a disadvantage in that fine particles of cement lodge in the nylon and absorbent cloth and eventually hydrate and clog the cloth making it useless. The fine cement particles must therefore be carefully and frequently cleaned from the laminate. Naturally, if desired both the aforesaid modifications could be employed together but this is not essential. When excess water has been removed from both the inner and outer surfaces of the cast concrete product, the pressure applied to cavity 83 and membrane 11 is released. It is generally of some importance that the pressures be released substantially simultaneously from cavity 83 and the membrane 11. The pressure applied to the inside of tubes 14 is also released. This step of releasing pressure from within the tubes 14 might also be carried out immediately after the membrane 18 is expanded, thereby reducing the need for vacuum to be applied to the tubes 14. With pressure reduced in the cavity 83, elasticity of the membrane 18 then applies a radially inward force to the metal formers 15 which in turn cause collapsible tubes 14 to deform and become flattened. This action is of course also assisted by elastic rings 23. If desired to assist in flattening of the tubes 14 a vacuum may be communicated with the interior of the tubes 14. Thereby a gap is created between the rubber membrane 18 and the inner surface of the concrete moulded article 80. x e inner mould 3 can then be drawn out of the moulded concrete article 80 as shown in Figure 8(d). The clamping means 25 holding the outer mould halves 60,61 together are released and low ai pressure is applied through the or each hole 9 into the space between the flexible membrane 11 and the outer shell 65. The permeable membrane 26 enables this pressure to be distributed evenly over the area of the flexible membrane 11. The permeable membrane 26 may be a woven nylon or the like. This air pressure gently presses the shell 65 of the mould halves 60, 6i away to create a peeling action of the membrane 11, much of which may remain stuck to the concrete. If this occurs - li ¬ the membrane 11 may be drawn radially outwardly by thereafter applying a vacuum through holes 9. This releases the membrane from the concrete with a peeling action which does not damage the body of the concrete article 80. The inner surface at least of the membrane 11 is relatively smooth leaving a relatively smooth finish on the concrete surface. The formed concrete can then be removed from the mould supported by the re-enforcement cage 2 which extends upwardly beyond the moulded concrete. It is of course also possible to use prestressed wires or rods in casting concrete articles of this type either in addition to or in replacement of the reinforcing cage 2 described in the foregoing. When this is done, it is preferred to move the cast article by gripping projecting lengths of the prestressed wires or rods. We refer now to the alternative preferred embodiment illustrated in figures 6 and 7 of the accompanying drawing. Essentially similar features in figures 1 to 5 and 6,7 have been given the same reference numerals. The outer mould construction 10 shown in figures 6 and 7 is essentially similar to figures 1 to 5 comprising two halves 60,61 with longitudinal adjoining flanges 4, a peripheral rigid shell wall 65 and a flexible liner 11. A permeable membrane similar to 26 may also be located between the liner 11 and the wall 65. The inner mould construction 3, is however, somewhat different and less complex than the construction shown in the figures 1 to 3. The construction comprises a generally flexible, annular impervious membrane 18 with peripherally spaced drainage galleries 20, filters 19 and retaining strips 31 similar to the previously described embodiment. The membrane 18 is attached at its upper and lower peripheral ends to end flanges of the inner mould construction. The upper end flange 90 only is illustrated in figure 6. Preferably the said ends of the membrane 18 are stretched outwardly such that the remainder of the membrane, by its own elasticity, is urged inwardly. The inner former of the inner mould construction 3 is formed by tubular member 91 formed by a woven Kevlar - polyester cloth coated with Mylar. Kevlar and Mylar are trade names representing long chain polyester materials. The material itself is extremely strong with minimal or no elasticity but capable of flexing in a similar manner to a relatively stiff cloth. The tubular member 91 needs to be accurately formed whereby when it is inflated under a predetermined pressure introduced into cavity 92 through opening 93, a substantially rigid former is created thereby of desired shape. In the example illustrated for creating tapered pole, the shape of the inflated tubular material 91 is an inverted truncated cone. To enable the de-sired shape to be formed guide arrangements attached to the tubular member 91 at peripherally spaced locations are provided. Each of the guide arrangements preferably comprises a pair of angle iron members 94 joined to the top and bottom flanges of the inner mould 3 and extending over the full length of the mould construction. The angle iron members 94 define between themselves a guide slot 95. Attached to the outer and the inner surfaces of the tubular member 91 are longitudinally extending metal support strips 96, 97. The inner strip 97 has guide members or plates 98 secured thereto at spaced locations along the length thereof and extending radially inwardly through the slot 95 between the angle iron members 94. A transverse strip member 99 on the plates 98 acts to limit the radial outward movement of the plates 98 and thereby the member 91. The arrangement thus described, enables the tubular member 91 to collapse inwardly by flexing its wall material when pressure is removed from the internal space 92. When, however, pressure is applied to the space 92 a rigid inner form of desired shape is formed by the member 91. This is the position illustrated in figure 6. In this condition, concrete of high slump consistancy can be introduced into the cavity 13, preferably using a tremmie introduction method as previously described. Alternatively, the concrete might be pumped into the cavity 13. Once the cavity is filled, the inner wall membrane 18 may be pressed outwardly by introducing pressurized gas into the cavity 83 through opening 100. Figure 6 illustrates schematically the situation prior to introduction of pressure into cavity 83 and figure 7 illustrates schematically the situation after introduction of such pressure. The process steps of operation of this mould assembly may be essentially the same as that previously described for the embodiment of figures 1 to 5. In figures 6 and 7, prestressed wires or rods 101 are illustrated in the mould cavity but it will be appreciated that- a reinforcing cage might also be used in addition to or in replacement of the prestressed wires or rods illustrated.

Claims: THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS : 1. A process for forming an elongate moulded article made from a settable material such as concrete comprising the steps of forming a mould defining an inner and an outer surface corresponding to opposed surfaces of " the moulded article formed therein, said mould being arranged whereby at least said inner surface is moveable relative to said outer surface; filling said mould with the settable material, compressing the settable material by movement of at least said inner surface relatively towards said outer surface to remove surplus liquid from said settable material such that the settable material is given the characteristic of being at least partially cured, and thereafter moving said inner surface relatively away from said outer surface to release said article from the mould and separating the mould from the said article. 2. A process according to claim 1 wherein the inner and the outer surfaces of said mould are arranged to form an elongated annular mould cavity therebetween. 3. A process according to claim 2 wherein said settable material is filled into said mould from one end of the mould under pressure, and where said inner surface of said mould is urged towards the outer surface of said mould prior to filling to thereby resist the pressure of said filling. 4. A process according to claim 2 wherein said settable material is filled into said mould using a tremmie adapted to traverse the length of said mould. 5. A process according to claim 3 or claim 4 wherein after filling of said mould said inner surface is further pressed outwardly against the settable material within said mould. 6. A process according to claim 4 wherein the inner surface of said mould includes liquid transferance means for draining said surplus liquid from the settable material. 7. A process according to anyone of claims 1 to 6 wherein at least during part of the process, pressure is applied to both inner and outer surfaces of the moulded article. 8. A process for casting an elongate annular concrete article of either constant or variable diameter in a mould assembly comprising an inner mould part and an outer mould part formed by at least two outer mould sections adapted to define an annular mould cavity therebetween, said process comprising the steps of:- (a) positioning said inner mould part within reinforcing elements; (b) positioning said outer mould sections around said inner mould part to define said annular mould cavity with said reinforcing elements located therein; (c) said inner mould part having a first peripherally positioned movable wall means and a second peripheral movable wall means surrounding said first wall means; (d) moving said first peripherally positioned wall means to a predetermined position and holding said first wall means at said predetermined position during introduction of uncured concrete into said mould cavity; (e) pressing said second peripheral wall means against concrete within said mould cavity whereby liquid transference means associated with said second wall means acts to drain liquid from said concrete within the mould cavity; and (f) at least during part of the time said second wall means is pressed against said concrete, applying pressure to the outer surface of the concrete within said mould cavity whereby said concrete is given the characteristic of being at least partially cured. 9. A moulding apparatus for producing an annular elongate article from a settable material such as concrete, said apparatus comprising an outer mould construction defining an inwardly facing mould surface adapted to form an outer surface of the article moulded therein, an inner mould construction adapted for location within said outer mould construction and defining an outwardly facing mould surface adapted to form an inner surface of the article moulded therein, said inner and outer mould constructions defining an elongated annular mould cavity, said inner mould construction further including means for moving said inwardly facing mould surface radially towards said outer mould construction and moisture transference means associated with said outwardly facing mould surface to pass moisture formed on the inner surface of the article moulded therein away from said inner surface when the settable material within the mould cavity is compressed by relative movement between said outwardly and said inwardly facing mould surfaces, and said apparatus further including means for introducing said settable material within said mould cavity. 10. Apparatus according to claim 7 wherein the inwardly facing mould surface of said outer mould construction is formed by- a liquid impervious flexible diaphragm, said outer moul .construction comprising an outer supporting shell and means being provided to introduce a pressure medium or. vacuum conditions between said membrane and said supporting shell to move said membrane towards or away from said shell. 11. Apparatus according to claim 9 or claim 10 wherein the inwardly facing mould surface of said outer mould construction carries a thin layer of a liquid absorbent material. 12. Apparatus according to claim 11 wherein the layer of absorbent material is comprised of an outer layer of porous material providing said inwardly facing mould surface and a layer of compressible liquid absorbent material located between the porous material layer and the remainder of the outer mould construction. 13. Apparatus according to claim 9 wherein said inner mould construction comprises a flexible nonexpandable tubular member adapted to form a rigid support structure when inflated but capable of flexing inwardly when noninflated. 14. Apparatus according to claim 9 wherein said inner mould construction comprises an inner supporting member and a movable outer wall construction adapted to move radially towards and away from said inner supporting member, means being provided between said outer wall construction and said inner support member to effect said radial movement. 15. Apparatus according to claim 14 wherein said moveable outer wall construction includes substantially rigid members slidable relative to each other and adapted to thereby radially expand or contract. 16. Apparatus according to any one of claims 13 to 15 wherein said movable outer wall construction includes a flexible membrane extending around said inner support member and the outer surface of said membrane forming the outwardly facing surface of said inner mould construction. 17. Apparatus according to claim 16 wherein said flexible membrane is permeable to liquid. 18. Apparatus according to claim 16 wherein liquid drainage galleries are provided associated with said membrane to drain surplus liquid from the mould cavity. 19. Apparatus according to claim 16 when appended to claim 14 wherein inflatable members are provided between said flexible membrane and said inner support member, said inflatable members being adapted to force said movable outer wall construction radially outwardly when inflated and enabling radial inward movement of the outer wall construction when the inflatable members are deflated.

Inventors: HUME GRAEME REGINALD, HUME, GRAEME, REGINALD
Applicants: HUME GRAEME REGINALD, HUME, GRAEME, REGINALD
Application year: 1986
Main classification: B28B21
IPC codes: B28B7, B28B21, B28B23