Tunnel mold, system and method for slip forming reinforced concrete structures with exposed rebars
DCFirst Claim
1. In a process for forming concrete structural components for road and bridge construction, wherein the resultant concrete structural components have exposed rebars for the later integration with additional concrete and/or mechanical structural elements, said additional concrete and/or mechanical structural elements selected from the group consisting essentially of sound walls, barricades, guard rails and any combination thereof, wherein the improvement comprises:
- A. Providing an iron work array wherein said iron work array comprises both (1) rebars for embedding within, and reinforcing, a first concrete highway structure and (2) rebars for extending from within said first concrete highway structure, for integration within and reinforcing a second concrete highway structure, to be formed at a later time;
B. Providing a machine assembly having a tunnel mold comprising1) A mold housing includinga) A hopper, a mold cavity and one or more channels,i. Said hopper comprising a means for receiving concrete and directing flow of said concrete into said mold cavity,ii. Said mold cavity defining a shape of concrete structure to be formed on an iron work array, andiii. At least one channel comprising an elongate opening extending through said housing, from front to back of said housing, and into and above said mold cavity,
each of said channel being defined by lateral side walls, an open bottom end thereof in communication said mold cavity, and a pair of fins from said open bottom end of each of said lateral side of each of said channel, which extends from each of said lateral side wall of said channel into said mold cavity; and
2) Means for supporting said mold housing on a slip mold transporterC. Slip forming said first concrete structure bya. Placing said machine assembly, equipped with said tunnel mold, in slip forming relation to said iron work array; and
b. Introducing concrete into said machine assembly for transfer into said tunnel mold assembly, while continuously moving machine assembly, equipped with said tunnel mold, over said iron work array, to slip form a first concrete structure with both rebars embedded in first concrete structure, and concrete free rebars, which extend from said iron work array embedded in said slip formed concrete structure.
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Abstract
A slip-mold having a housing having (a) concrete hopper having (b) means for distribution of quick set concrete within said hopper, (c) a mold cavity, and (d) at least one tunnel, in communication with said mold cavity, and extending through said housing from the leading to the trailing end of said housing. The tunnel through the housing is of sufficient height and width, and positioned within said mold housing, to permit rebars, extending from an iron work array, to pass through said mold cavity without becoming embedded in concrete, concurrent with the formation of a slip formed concrete structure on a portion of said iron work array.
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Citations
22 Claims
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1. In a process for forming concrete structural components for road and bridge construction, wherein the resultant concrete structural components have exposed rebars for the later integration with additional concrete and/or mechanical structural elements, said additional concrete and/or mechanical structural elements selected from the group consisting essentially of sound walls, barricades, guard rails and any combination thereof, wherein the improvement comprises:
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A. Providing an iron work array wherein said iron work array comprises both (1) rebars for embedding within, and reinforcing, a first concrete highway structure and (2) rebars for extending from within said first concrete highway structure, for integration within and reinforcing a second concrete highway structure, to be formed at a later time; B. Providing a machine assembly having a tunnel mold comprising 1) A mold housing including a) A hopper, a mold cavity and one or more channels, i. Said hopper comprising a means for receiving concrete and directing flow of said concrete into said mold cavity, ii. Said mold cavity defining a shape of concrete structure to be formed on an iron work array, and iii. At least one channel comprising an elongate opening extending through said housing, from front to back of said housing, and into and above said mold cavity,
each of said channel being defined by lateral side walls, an open bottom end thereof in communication said mold cavity, and a pair of fins from said open bottom end of each of said lateral side of each of said channel, which extends from each of said lateral side wall of said channel into said mold cavity; and2) Means for supporting said mold housing on a slip mold transporter C. Slip forming said first concrete structure by a. Placing said machine assembly, equipped with said tunnel mold, in slip forming relation to said iron work array; and b. Introducing concrete into said machine assembly for transfer into said tunnel mold assembly, while continuously moving machine assembly, equipped with said tunnel mold, over said iron work array, to slip form a first concrete structure with both rebars embedded in first concrete structure, and concrete free rebars, which extend from said iron work array embedded in said slip formed concrete structure. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A system for the slip forming of a reinforced concrete structure having both embedded and exposed rebars, said system comprising:
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A. Providing a machine assembly for continuously molding of a reinforced first concrete highway structure upon an iron word array by slip forming concrete with a tunnel mold, said tunnel mold comprising, 1) A mold housing including a) A hopper, a mold cavity and one or more channels, i. Said hopper comprising a means for receiving concrete and directing flow of said concrete into said mold cavity, ii. Said mold cavity defining a shape of concrete structure to be formed on an iron work array, and iii. At least one channel comprising an elongate opening extending through said housing, from front to back of said housing, and into and above said mold cavity,
each of said channel being defined by lateral side walls, an open bottom end thereof in communication said mold cavity, and a pair of fins from said open bottom end of each of said lateral side of each of said channel, which extends from each of said lateral side wall of said channel into said mold cavity; and2) Means for supporting said mold housing on a slip mold transporter B. Means for transfer of unset concrete into said tunnel mold assembly, while continuously moving machine assembly, equipped with said tunnel mold, over said iron work array, to slip form a first concrete structure with both rebars embedded in said first concrete structure, and concrete free rebars, which extend from said iron work array embedded in said slip formed concrete structure; and C. Means for guidance and control of movement over said machine assembly relative to said iron work array. - View Dependent Claims (9, 10, 11, 12, 13, 14)
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15. A tunnel mold, comprising:
A. A mold housing including 1) A hopper, a mold cavity and one or more channels, i. Said hopper comprising a means for receiving concrete and directing flow of said concrete into said mold cavity, ii. Said mold cavity defining a shape of concrete structure to be formed on an iron work array, and iii. At least one tunnel comprising an elongate channel extending through said housing, from front to back of said housing, and into and above said mold cavity, each of said tunnel being defined by a pair of lateral side walls, an open bottom end thereof in communication said mold cavity, and a pair of fins from said open bottom end of each of said lateral side walls of each of said tunnel, which extends from each of said lateral side wall of said channel into said mold cavity; and 2) Means for supporting said mold housing on a slip mold transporter. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22)
Specification