PROCESS FOR THE MANUFACTURING OF A LOST CASING AND FRAMES FOR USE DURING SAID PROCESS

Abstract: This invention deals with the manufacturing of a lost casing of polygonal horizontal section throughout its height of inner and outer wall,by making use of an assembly jig made itself from standard elements(1,2,2a,3,4,5) such as frames (6-9 and beams, sothat a series of jigs of different dimensions can be made. The casing being made on said jig by releasebly attaching plates(12,13) to the jig and by interconnecting said plates in seamless way. Inner and outer casing can be made on separate jigs. A series of standard frames may be applied.

Description: The invention relates to a process for the manufacturing of a double-walled hollow lost casing with plane inner and outer surfaces, which casing after its manufacturing is filled between its inner and outer walls with a hardening material such as concrete, said manufacturing process comprising, precutting a plurality of flat sheets each having a predetermined size and shape defined by their respective positions in the inner and outer wall respectively of the casing, assembling a number of said sheets by welding their edges upon each other, such that an inner wall of the casing is obtained having in each horizontal section of the casing a polygonal shape, and further assembling an other number of said precut sheets by welding to form an outer wall, which obtains a corresponding polygonal shape in each horizontal section, which sheets in the lower part of the casing are assembled such that the lower edges of the lowermost sheets of inner and outer wall respectively form a sharp edge. Such a process can be deduced from the international patent application WO 87/03026, laid open for inspection. This application describes a lost casing for the manufacturing of e.g. a pier or a jetty which lost casing comprises an inner wall and an outer wall, which both in each horizontal section have the shape of a polygonal whilst the outer wall at least in the lower region flares downwardly and outwardly and forms with the inner wall, which also has a downwardly and outwardly widening portion, a sharp bottom edge. This casing is manufactured from transverse connecting members between inner and outer wall plates. This hollow steel casing can be provided with reinforcing rods and at a suitable moment during the manufacturing of e.g. a pier can be filled with concrete to form a rigid column. If the dimensions of such a lost casing are not too large handling of the respective precut plates of rectangular or trapezium shape does not form a severe handling problem. However, with increase of the dimensions support becomes necessary during the manufacturing, because the not yet finished casing has no inherent stability. It is known to support the respective plates during manufacturing by means of rather primitive workshop measures which in practice do not satisfy and are not suitable with increase of the dimensions. Purpose of the invention is to improve the manufacturing and according to the invention this is achieved in that at least the assembly of the plates of the inner wall takes place on an assembly jig of the type as described later on, by releasably attaching the sheets of the inner wall to horizontal beams of said jig, which beams extend parallel to the planes of the respective sheets of the said inner wall said sheets being interconnected for instance by welding after their attachment, which inner wall after or during its manufacturing is provided with outwardly projecting spacers with connecting means such as bolts and nuts upon which the sheets of the outer wall are attached. By making use of an assembly jig the outer shape of which corresponds in three dimensions to the inner shape of the lost casing to be manufactured or in case of the outer wall to the inner shape of said outer wall proper and precise manufacturing becomes possible by subsequent attachment of the sheets to the horizontal beams of the assembly jig. After completion of the inner wall of the casing sufficient stability is obtained to detach it from the assembly jig but according to the invention it is preferred that prior to such a detachment the sheets of the outer wall are interconnected with each other after their attachment to the said spacers. This means that also the outer wall is assembled sheet by sheet by attachment on spacers of an inner wall supported by the assembly jig. According to the invention the outer wall can be made on a separate assembly jig as well which outer wall after its completion is released from its assembly jig, is lifted and is lowered over the inner wall and connected with the said spacers. The completed double-walled casing then can be removed from the assembly jig which supports the inner wall and then be used for further transportation and handling to achieve its position and function at the desired location. To facilitate the assembly the outer wall sheets are provided with openings which correspond in place and distance to the place and distance of the spacers, said spacers having a length such that they can extend through the said openings, have an abutment for the sheets engaging the edges of the openings and have means for connecting the outer wall or wall sheets to the spacers. It will be understood that prior to attaching the outer wall or wall sheets, concrete reinforcing rods are attached to the outer face of the inner wall of the lost casing with spacing elements between said wall and said rods. The hollow lost casings as known from the above-mentioned international patent application WO 87/03026 can have different dimensions. Its polygonal shape can be regular or irregular and its height can be different as well as width or length. All assembly takes place, however, from flat sheets the edges of which are interconnected in such a way that a smooth surface is obtained, which means that there are no transversely extending flanges used for interconnecting purposes. Said flat sheets are rectangular or trapezium-shaped in general which simplifies the assembly and gives rigidity to the casing after manufacturing and prior to being filled with a hardening material. Said polygonal shape composed of flat sheets which extend at angles with respect to each other opens the way to use an assembly jig which easily allows variations in shape and dimensions. According to the invention an arrangement of a lost casing and an assembly jig is provided in accordance with claim 6. By changing the number of vertical frames and adapting the length of horizontal beams assembly jigs can be assembled which in a horizontal section of plan view have differences in polygonal shape such as longer or shorter parallel sides. The possibility to adapt the assembly jig to different dimensions and shapes is increased in case according to the invention each vertical frame is composed of a plurality of rectangular subframes and at least one triangular subframe, which rectangular subframes have the same width, seen in the plane of each vertical frame, and a height chosen out of a series of standard heights. Preassembly of parts of the jig can be obtained in case subframes of one specific standard height by means of horizontal beams are interconnected to form a tridimensional rectangular parallelepiped. The same holds true in case at least two triangular frames are interconnected by means of horizontal beams to form a tridimensional frame, the length of said horizontal beams corresponding to the horizontal distance between adjacent vertical frames. The assembly jig of the arrangement according to the invention moreover may be composed of two vertical frames or subframes placed with their planes at an angle with respect to each other and interconnected by horizontal beams such that in plan view they have the shape of a triangle or equal-sided trapezium. As an alternative the assembly jig of the arrangement according to the invention may comprise vertical frames each having an outer beam which at least at the lower ends slope outwardly and downwardly, opposite outer beams of the jig being interconnected by horizontal beams at least at top and lower end, which horizontal beams span the width of the jig. The opposite outer beams may be interconnected by a triangular lattice frame between them. A plurality of said frames can be interconnected to form a tridimensional frame as part of the jig. Several types of frames and subframes have been described. They are easy to manufacture and assemble. They can be combined in any suitable way and in accordance with the demand at the side of the work dictated by the circumstances. The pre-cut plates for inner and outer wall are for the majority rectangular plates. At the inclined wall portions, in particular at the corners, the use of trapezium-shaped plates can be advantageous. The detachability of the outer wall sheets in some cases can have the advantage that, after removal of the connecting means, said outer wall sheets can be removed or the entire wall be lifted off, once the concrete filling has set sufficiently. The invention now will be explained with reference to the drawings. Fig. 1 shows schematically in top view a jig according to one embodiment of the invention. Fig. 2 is a cross section according to the line II-II of Fig. 1 with the sheets of the inner and outer wall being added. Figures 3 shows in perspective the embodiment of the jig of Figures 1 and 2. Fig. 4 shows schematically in top view the way standard frames can be placed and interconnected in a manner which differs from the one shown in Fig. 1. Figures 5, 6 and 7 show in a vertical side view different possibilities for assembling the standard frame from subframes. Figures 8 and 9 show in perspective view several possibilities of making frames from tridimensional subframes. Fig. 10 shows in vertical cross section schematically a jig for the inner wall of the lost casing and Fig. 11 shows in the same way as Fig. 10 a vertical cross section through the jig for manufacturing the outer wall of the lost casing. Fig. 12 shows schematically another embodiment for the frame and Fig. 13 shows schematically a lattice work for a frame of the type shown in Fig. 12. The assembly jig shown in Figures 1, 2 and 3 comprises standard frames 1 placed in vertical planes which are interconnected by a plurality of horizontal beams 2. These are horizontal beams 2 at the inner side as well as horizontal beams 2a at the outer side to which the plates of the inner wall of the casing can be attached. Said beams may have a suitable profile such as the I-profile shown in Figures 2 and 3. Said vertical standard frames 1 are interconnected to form large side frames by means of long beams 2, 2a. Said frames are substantially rectangular in shape seen in top view and front view respectively. The rearside formed by the vertical beam 3 extends from top to bottom. The front beams 4 of the standard frames 1 extend from the top towards the outwardly and downwardly inclined beams 5. Instead of broad frames as shown for the long sides of the jig shown in Figures 1 and 3, frames of smaller width can be used such as the frames 6 and 7 or 8 and 9 as shown in Figure 1. The smaller frames like the frames 8 and 1 may have on the outer side horizontal beams 10 which together with sides frames 11 form a trapezium. The long frames can be composed of a plurality of smaller frames. All frames can make use of sections of different cross section such as U-sections, I sections, L-sections and the like. In the cross section shown in Figure 2 the plates 12 and 13 of the inner wall of the lost casing are shown attached to the outer flanges of the beams 2a. Said sheets can be interconnected by welding as e.g. shown at 14. Bolts 15 are fixed to said sheets, e.g. by welding or otherwise. In Fig. 2 the outer sheets for the outer wall of the lost casing are indicated at 18. They are attached to the bolts by means of nuts 19 on a screw threaded end of the bolt 15. The distance between inner and outer plate 12 and 18 respectively is obtained by means of a bush 20 shifted over the bolt 15. Instead of a bush it is also possible to use a collar 20′. After manufacturing the casing it can be released from the jig by removing the connection between the beams 2a and the inner plates 12 e.g. Fig. 4 shows a slightly different embodiment. Again frames 1 are used interconnected by horizontal beams such as 2 and 2a. Also at the sides smaller frames 6 are used. The difference is that inbetween use is made either of triangular frames 21 by placing two standard frames 1 at a sharp angle to each other or by using an individual standard frame 1′ parallel to the main frames 1 of the small frame 7 held in place by means of additional beams as indicated with the interrupted line 22. Between the interconnected frames a reinforcing structure is shown formed by crossing means 22 and 23 which can be continuous or as shown at 24 made from short pieces. Fig. 5 shows a standard frame assembled from a plurality of subframes. The subframes 25 and 26 have the same height. Frame 27 has a height which is half the height of the frames 25 or 26 respectively and frame 28 is about 1/3 in height of frame 26. This assembly is completed by means of the triangular frame 29. In Fig. 6 the standard frame is composed of a subframe 30 extending over the entire height combined with the triangular subframe 29. In Fig. 7 two subframes 25 and 26 are combined with two frames of the height of the frame 28. Further two square elements are used as well as two small triangular frames 32. The width in the plane of the drawing is the same for all rectangular subframes. Fig. 8 shows tridimensional rectangular subframes 33, 34 and 35 of different heights but equal other dimensions. This standard frame is combined with a triangular frame 36 having a distance between the vertical beams 37 and 38 which is equal to the distance between the vertical beams 39 and 40. Fig. 9 shows a subframe of triangular horizontal cross section indicated with 41, combined with a triangular frame 36. The width of the sides of the subframe 41 has to be equal to the width of the vertical rectangular side of the frame 36. Fig. 10 shows in vertical cross section the jig 42 for manufacturing the inner wall 43. Fig. 11 shows at the same scale the jig 44 for manufacturing the outer wall 45. In Fig. 10 said outer wall 45 is placed over the inner wall to form the lost casing. The means interconnecting inner and outer wall are not shown, but can be the means shown in Fig. 2. Fig. 12 shows a tridimensional frame with outer beams 46, 47, which have a downwardly and outwardly extending lower part 48, 49 respectively and which are interconnected by horizontal beams 50 and 51 which span the entire width of the jig. Said frames 46, 47, 48, 49, 50, 51 can be combined into tridimensional frames by means of horizontal beams like 52. To give said trimensional frames stability several possibilities do exist. Fig. 13 shows one possibility by placing between the vertical beams 46 and 47 a triangular lattice work which can fill the entire inner space in vertical and horizontal longitudinal and transverse direction.

Claims: 1. Process for the manufacturing of a double-walled hollow lost casing with plane inner and outer surfaces (12, 13, 18), which casing after its manufacturing is filled between its inner and outer walls (12, 13, 18) with a hardening material such as concrete, said manufacturing process comprising, precutting a plurality of flat sheets each having a predetermined size and shape defined by their respective positions in the inner and outer wall respectively of the casing, assembling a number of said sheets by welding their edges (14) upon each other, such that an inner wall (12, 13) of the casing is obtained having in each horizontal section of the casing a polygonal shape, and further assembling an other number of said precut sheets by welding to form an outer wall (18), which obtains a corresponding polygonal shape in each horizontal section, which sheets in the lower part of the casing are assembled such that the lower edges of the lowermost sheets (13, 18) of inner and outer wall respectively form a sharp edge, characterized in that, at least the assembly of the plates of the inner wall (12, 13) takes place on an assembly jig (1-11) in accordance with claim 6, by releasably attaching the sheets of the inner wall (12, 13) to horizontal beams (2a) of said jig, which beams (2a) extend parallel to the planes of the respective sheets of the said inner wall (12, 13) said sheets being interconnected for instance by welding after their attachment, which inner wall (12, 13) after or during its manufacturing is provided with outwardly projecting spacers (15) with connecting means (19, 20) such as bolts and nuts (15, 19) upon which the sheets of the outer wall (18) are attached. 2. Process as claimed in claim 1, characterized in that the sheets of the outer wall (18) are interconnected with each other after their attachment to the said spacers (15-20). 3. Process as claimed in claim 1, characterized in that the outer wall (18, 45) is made on a separate assembly jig (44), which outer wall after its completion is released from its assembly jig (44), is lifted and is lowered over the inner wall (43) and connected with the said spacers (15-20). 4. Process as claimed in claim 3, characterized in that the sheets of the outer wall (18) are provided with openings which correspond in place and distance to the place and distance of the spacers (15), said spacers having a length such that they can extend through the said openings, have an abutment (20) for the sheets engaging the edges of the openings and have means (19) for connecting the outer wall or wall sheets to the spacers. 5. Process as claimed in claim 2 or 3, characterized in that prior to attaching the outer wall (18) or wall sheets, concrete reinforcing rods are attached to the outer face of the inner wall of the lost casing with spacing elements between said wall and said rods. 6. Arrangement of a lost casing and an assembly jig, said casing comprising an inner wall (12, 13) and an outer wall (18), each made of flat sheets of predetermined size and shape and welded upon each other at the edges, such that the inner wall (12, 13) in each horizontal section is polygonal, the outer wall has a corresponding polygonal shape and in the lower part of the casing the inner and outer wall (12, 13; 18) meet to form a sharp edge at the lower end of the outer wall (18), characterized in that the assembly jig comprises a three-dimensional structure of vertical frames (1) and horizontal beams (2, 2a) which interconnect said frames (1) and which extend parallel to the planes of the sheets of the inner and/or outer wall (12, 13, 18) of the double-walled casing, which vertical frames (1) are placed in vertical planes perpendicular to the planes of inner and outer wall respectively of the casing and parallel to or at an angle to each other and each comprising vertical and horizontal beams (2, 3, 4) as well as downwardly and outwardly sloping beams (5, 29, 32, 36, 48, 49) in at least the lower outer region of each frame, said horizontal beams (2a), which interconnect the vertical frames being at any rate present upon the outwardly turned faces of the vertical frames for the releasably attachment thereon of the casing sheets. 7. Arrangement as claimed in claim 6, wherein each vertical frame (1) is composed of a plurality of rectangular subframes (25-31) and at least one triangular subframe (29, 32), which rectangular subframes have the same width, seen in the plane of each vertical frame, and a height chosen out of a series of standard heights. 8. Arrangement as claimed in claim 7, wherein subframes of one specific standard height by means of horizontal beams are interconnected to form a tridimensional rectangular parallelepiped. 9. Arrangement as claimed in claim 7 or 8, wherein at least two triangular frames are interconnected by means of horizontal beams to form a tridimensional frame, the length of said horizontal beams corresponding to the horizontal distance between adjacent vertical frames. 10. Arrangement as claimed in claim 7 or 8, characterized in that it is composed of two vertical frames or subframes placed with their planes at an angle with respect to each other and interconnected by horizontal beams (21, 22) such that in plan view they have the shape of a triangle or equal-sided trapezium. 11. Arrangement as claimed in claim 6, characterized in that it comprises vertical frames each having an outer beam (46, 47) which at least at the lower ends slope outwardly and downwardly (48, 49), opposite outer beams (46, 47) of the jig being interconnected by horizontal beams (50, 51) at least at top and lower end, which horizontal beams span the width of the jig. 12. Arrangement as claimed in claim 10, characterized in that between the opposite beams of the frames there is a triangular lattice frame (56).

Inventors: MASSOUDI, AHMAD SHAGHAYEGH ALLEY
Applicants: DARYA PAYE JETTY CO., LTD.
Application year: 1989
Main classification: E02D23
IPC codes: E02B3, E02B17, E02D23