WO2000014339A1

WO2000014339A1 - Method of constructing a wall element

Info

Publication number: WO2000014339A1
Application number: PCT/IB1999/001498
Authority: WO
Inventors: Alethea Rosalind Melanie Hall
Original assignee: Alethea Rosalind Melanie Hall
Priority date: 1998-09-03
Filing date: 1999-09-02
Publication date: 2000-03-16
Also published as: AU5383099A

Abstract

A method of constructing a wall element, e.g. a section of a harbour wall, which is substantially rectangular in plan view and which comprises a main section and a front section, comprises locating a tube (10) of a flexible material divided by dividing walls of a flexible material into an array of compartments (14) running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by the dividing walls has a honeycomb structure, with a first end of the tube on a base and a second end of the tube above the first end of the tube, the tube having a main section (16) corresponding to the main section of the wall element and a front section (18) corresponding to the front section of the wall element, wherein the compartments (14B) of the front section of the tube have a smaller cross-sectional size than the compartments (14A) of the main section of the tube; and filling substantially all of the compartments of the tube with a filler material wherein some or all of the compartments of the front section of the tube are filled with a filler material which includes a binder to form the wall element.

Description

METHOD OF CONSTRUCTING A WALL ELEMENT

BACKGROUND TO THE INVENTION

This invention relates to a method of constructing a wall element, to a method of constructing a wall such as a harbour or dam wall from various wall elements, and to the wall elements and walls themselves.

It is well known to form support structures such as roadways, canal or river or bank linings, mine packs, sea walls, or the like from a material having a honeycomb structure, i.e having a plurality of compartments or cells divided by dividing walls, each compartment or cell being filled with a suitable filler material. Examples of such materials for use in these support structures are Hyson-Cells from M & S Technical Consultants & Services (Pty) Limited, Geoweb from Presto Products Co, Tenweb from Tenax Corp, Armater from Crow Company, Terracell from Webtec Inc, Envirogrid from Akzo Nobel Geosynthetics Co and Geocells from Kaytech. However, there is always a need for new methods of utilising this tube material.

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a method of constructing a wall element or the like which is substantially rectangular in plan view and which comprises a main section and a front section which method comprises the steps of:

(1) locating a tube of a flexible material divided by dividing walls of a flexible material into an array of compartments or cells running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by the dividing walls has a honeycomb structure, with a first end of the tube on a base and a second end of the tube above the first end of the tube, the tube having a main section corresponding to the main section of the wall element and a front section corresponding to the front section of the wall element, wherein the compartments of the front section of the tube have a smaller cross- sectional size than the compartments of the main section of the tube; and

(2) filling substantially all of the compartments of the tube with a filler material wherein some or all of the compartments of the front section of the tube are filled with a filler material which includes a binder; to form the wall element.

The cross-sectional size of a compartment is the cross-sectional area thereof at right angles to the axis of the compartment. The wall element is of particular use in the construction of a harbour or dam wall or a snow wall or the like, in which case the front section of the wall element is adapted to face the water or snow in use. The wall element may also be used in the construction of a wall in a mine or the like.

The compartments of the main section of the tube may also vary in size from one row to the next, if desired. The use of compartments with different cross-sectional sizes is described in more detail in co-pending application PCT/IB 99/00967 which is incorporated herein by reference.

The filler material may be for example gravel, sand, snow, or the like.

By a binder there is meant a cementitious binder or a bituminous binder or any other binder which provides the filler material/binder mixture with sufficient rigidity and strength in use.

Optionally, some of the outer compartments of the main section of the tube, i.e the compartments around the edge of the main section of the tube, may also be filled with the mixture of filler material and binder as described above.

Optionally, the filler material and binder may be mixed with a suitable foam or foaming agent before being filled into the compartments to reduce the weight of the material when set.

The base on which the wall element is formed may be a ground surface or a top surface of a previously formed wall element. The tube may be supported in position using any suitable support means, prior to being filled with a filler material.

For example, the support means may comprise a series of flexible strings or rigid stays located through suitable rows and columns of compartments, generally at or near the edges of the tube, which flexible strings or rigid stays are attached to fixed objects to support the tube with the first end of the tube on the base and the second end of the tube above the first end.

Thus, for example, as the tube is substantially rectangular in plan view, a string or a stay may be located in at least a row or a column of compartments at or near each of the four edges of the tube.

The use of flexible strings or rigid stays to support a tube in position is described in more detail in co-pending application PCT/IB 99/00965 , which is incorporated herein by reference.

Further alternatively the outer walls of the tube may be made sufficiently rigid so that the tube is self-supporting.

In addition, suitable weights may be attached to the walls of the tube to hold the tube down before being filled with the filler material.

The tube and the dividing walls may be made from any suitable flexible material. Although the material must possess some degree of flexibility, the degree of flexibility may range from very flexible up to semi-rigid. The flexible material may be for example a plastics material such as for example a co-extruded or a bi-axially extruded plastics material; a plastics mesh material; a plastics laminate material such as for example a laminate of a plastics material and a metallic material or a textile material; a metallic material; a woven or non-woven textile material; a paper or cardboard material; and the like.

The flexible material is preferably a suitable plastics material.

The tube may have any suitable height and any suitable compartment size. For example, the height of the tube may range from 50 mm to 10 m and each compartment may have a wall length of from 5 mm up to 2 m.

The compartments in the tube may have any suitable cross-section, such as triangular, square, hexagonal or octagonal, but preferably have a square cross-section, i.e each compartment is defined by four walls of substantially equal length.

The front section of the tube may slope outwardly from top to bottom.

According to a second aspect of the invention there is provided a method of constructing a wall, or a section or a pillar of a wall, from a plurality of wall elements, each wall element being substantially rectangular in plan view and comprising a main section and a front section, each wall element being formed using a tube of a flexible material divided by dividing walls of a flexible material into an array of compartments or cells running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by the dividing walls has a honeycomb structure, the tube having a main section corresponding to the main section of the wall element and a front section corresponding to the front section of the wall element, wherein the compartments of the front section of the tube have a smaller cross- sectional size than the compartments of the main section of the tube, which method comprises the steps of:

(a) locating a first tube with a first end of the first tube on a base and a second end of the first tube above the first end of the first tube;

(b) filling substantially all of the compartments of the first tube with a filler material wherein some or all of the compartments of the front section of the first tube are filled with a filler material which includes a binder, to form a first wall element;

(c) locating a second tube with a first end of the second tube on the first wall element and a second end of the second tube above the first end of the second tube, and with the front section of the second tube on top of or overlapping the front section of the first wall element;

(d) filling substantially all of the compartments of the second tube with a filler material wherein some or all of the compartments of the front section of the second tube are filled with a filler material which includes a binder, to form the second wall element;

(e) locating a third tube on the second wall element in the same manner as the second tube is located on the first wall element, and so on, and filling substantially all of the compartments of the third and subsequent tubes with a filler material wherein some or all of the compartments of the front sections of the third and subsequent tubes are filled with a filler material which includes a binder, to form the third and subsequent wall elements, and thus to form the wall or wall section. The first tube, the second tube and the subsequent tubes may all be of substantially the same overall cross-sectional size, with the main sections and front sections of each of the tubes also being of substantially the same overall cross-sectional size.

Alternatively, the second tube may have a smaller overall cross-sectional size than the first tube, the third tube may have a smaller overall cross-sectional size than the second tube and so on, so that, in use, the front section of each succeeding tube is stepped back from the front section of the underlying tube, so that a wall or a wall section formed therefrom has a front side which slopes inwardly from the base to the top.

A sheet of a mesh material or the like may be located between each of the tubes located one on top of another, to reinforce the wall or wall section formed therefrom.

When the method set out above is used to form a wall section or a wall pillar or the like, one or more further wall sections or wall pillars may be formed as set out above, one adjacent to another, so that adjacent sides of adjacent wall sections or pillars protrude into and thus interlock with each other, to form a wall.

In order to achieve this interlocking, the tubes and dividing walls may be so designed that a wall or walls of each compartment includes one or more hollow protrusions or one or more hollow recesses or both, for interlocking of adjacent compartments. This is described in more detail in co-pending application PCT/IB 99/00964 which is incorporated herein by reference. The wall sections may be formed so that the second wall section is stepped back from the first wall section, the third wall section is stepped back from the second wall section and so on, so that when the wall is a harbour or dam wall or the like, the water meets the front sections of the elements at an angle other than 90°.

Alternatively, the wall sections may be formed one adjacent another so that, in plan view, the wall so formed has a straight front wall. In other words, the first, second and subsequent wall sections are located exactly side by side, with no steps there between.

A platform may be laid on top of the main sections of the topmost wall elements in, for example, a harbour wall, to form a road or walk way.

According to a third aspect of the invention there is provided a wall element or the like formed as described above.

According to a fourth aspect of the invention there is provided a wall or the like, formed as described above.

According to a fifth aspect of the invention there is provided a tube of a flexible material, divided by dividing walls of a flexible material into an array of compartments or cells running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by dividing walls has a honeycomb structure, the tube being rectangular in plan view and having a main section and a front section, the compartments of the front section having a smaller cross-sectional size than the compartments of the main section, for use in a method of constructing a wall element or a wall as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a first type of tube for the formation of a wall element according to the invention; Figure 2 is a schematic sectioned side view of a first wall section or pillar formed from a plurality of wall elements, in the construction of a wall such as a harbour wall according to the invention; Figure 3 is a schematic plan view of a first harbour wall according to the invention; Figure 4 is a schematic sectioned side view of a second wall section or pillar formed from a plurality of wall elements, in the construction of a wall such as a harbour wall according to the invention; Figure 5 is a schematic sectioned side view of a third wall section or pillar formed from a plurality of wall elements, in the construction of a wall such as a harbour wall according to the invention; Figure 6 is a schematic sectioned side view of a harbour quay formed according to the method of the invention; Figure 7 is a schematic plan view of a second harbour wall according to the invention; and Figures 8 are schematic sectioned side views of wall sections or pillars to 10 formed in conjunction with piling.

DESCRIPTION OF EMBODIMENTS

The crux of the invention is a method of constructing a wall element and then constructing a wall from such wall elements, and to the wall elements and the wall so made. This will be described in more detail with reference to the accompanying drawings.

Referring to Figure 1 , there is shown a tube 10 of a flexible material divided by dividing walls 12 of a flexible material into an array of compartments 14 running the length of the tube 10. The compartments 14 are arranged in rows and columns so that the tube 10 has a honeycomb structure.

The tube 10 is rectangular in plan view and includes a main section 16 and a front section 18.

The front section 18 slopes outwardly from the top to the bottom, at any suitable angle, for example an angle of 70° .

The compartments 14A of the main section 16 of the tube 10 have a greater cross-sectional size than the compartments 14B of the front section 18 of the tube 10. The compartments 14A may themselves vary in cross-sectional size as illustrated. The construction of a wall section or pillar 20 utilising the tube 10 will be described in more detail with reference to Figure 2. Referring to Figure 2, there is shown a harbour environment, including a harbour floor 22 and water 24.

A first wall element 20A is constructed on the harbour floor 22 as described below.

A tube 10 is located in position on the harbour floor 22 and is held in position in any suitable manner, for example by attaching flexible or rigid stays to each corner of the tube 10 and then securing the stays to the harbour floor or to any surrounding solid structure.

Thereafter, the compartments 14A of the main section 16 of the tube 10 are filled with a filler material such as sand or gravel or the like. The compartments 14B of the front section 18 of the tube 10 are filled with a mixture of a filler material and a binder, for example a mixture of gravel or sand and a cementitious binder forming a pumpable concrete. As the front section 18 of the tube 10 and the corresponding front section of the wall element 20A is the section which is designed to meet the water 24 and thus any wave action, this section needs to be stronger than the main section of the wall element 20 A.

Once the wall element 20 A has been constructed, a similar wall element 20B is constructed on top of the wall element 20A, and so on with the wall elements 20C and 20D, to form a pillar 26. Thereafter, a concrete slab 28 may be formed on the front face of the pillar 26, to protect the pillar 26.

As an option, the outer walls of the tubes 10 may include an extension or petticoat which, in use, is folded inwardly, to prevent the egress of filler material from the outer compartments of the tubes 10 in use.

Referring now to Figure 3, in the construction of a harbour wall 30, a first pillar 26A is constructed adjacent an existing harbour wall or other solid object 32, as described above. Thereafter, second, third, fourth and fifth pillars 26B, 26C, 26D and 26E are constructed in the same manner, ensuring that the adjacent sides of the wall element 20 of the pillars 26 protrude into and thus interlock with each other, to form the harbour wall 30.

From Figure 3, it can be seen that the pillars 26A to 26E are stepped in relation to one another, so that the water in the harbour meets the front sections of the wall elements 20, with their concrete slabs 28, at an angle other than 90°. This assists in dissipating wave action and the like.

Referring to Figure 4, there is shown a wall section 40 formed from a plurality of wall elements 40A, 40B, 40C, 40D, 40E and 40F.

Each wall element 40A to 40F is formed using a tube 42 of a flexible material divided by dividing walls (not shown) of a flexible material into an array of compartments (not shown) running the length of the tube 42, which is then filled with a filler material. Each tube 42 is rectangular in plan view and includes a main section 44 and a front section 46.

The compartments of the main section 44 of the tube 42 have a greater cross- sectional size than the compartments of the front section 46 (which front sections 46 are all shaded) of the tube 42.

The wall section 40 may be constructed from the plurality of wall elements 40A to 40F in the same manner as the wall section 20 of Figure 2 is constructed.

A concrete slab 48 may be formed on the top of the wall section 40 to form a suitable top surface.

Referring to Figure 5 there is shown a wall section 50 formed from a plurality of wall elements 50A, 50B, 50C, 50D, 50E and 50F.

Each wall element 50A to 50F is formed using a tube 52 of a flexible material divided by dividing walls (not shown) of a flexible material into an array of compartments (not shown) running the length of the tube 52, which is then filled with a filler material.

Each tube 52 is rectangular in plan view and includes a main section 54 and a front section 56.

The compartments of the main section 54 of the tube 52 have a greater cross- sectional size than the compartments of the front section 56 (which front sections 56 are all shaded) of the tube 52. Further, as can be seen from Figure 5, the tube 52 from which the wall element 50A is formed as a greater overall cross-sectional size than the tube 52 from which the wall element 50B is formed, which in turn has a greater overall cross- sectional size than the tube 52 from which the wall element 50C is formed, and so on.

It can also be seen that the front section 56 of each tube 52 is stepped back from the front section 56 of the underlying tube 52 so that the wall section 50 formed from the tubes 52 has a front side 57 which slopes inwardly from the base to the top.

The wall section 50 may be constructed from the plurality of wall elements 50A to 50F in the same manner as the wall section 20 of Figure 2 is constructed.

Again, a concrete slab 58, which may have a complex profile to provide ducting 59 for services, may be formed on top of the wall section 50 to provide a suitable top surface, and may be tied back with tie bars 60.

Referring to Figure 6, there is shown a typical section through a harbour quay 61. The harbour quay 61 is formed from a plurality of wall elements 62 A to 621.

Again, each wall element 62A to 621 is formed using a tube 64 of a flexible material divided by dividing walls 66 of a flexible material into an array of compartments 68 running the length of the tube 64, which is then filled with a filler material. As shown in Figure 6, at the left hand side of each of the tubes 64 is a shaded section 70. This shaded section 70 represents the front section of each tube 64 and includes compartments (not specifically illustrated) having a smaller cross- sectional size than the compartment 68 of the main section 72 of the tube 64.

The wall elements 62A to 621 are formed from the tube 64 in the same manner as the wall elements 20A to 20D of the wall section 20 of Figure 2 are formed. In this regard, the compartments in the front section 70 of each tube 64 are filled with a filler material containing a binder, preferably a cementitious material, as it is this side of the harbour quay 60 which takes the force of the water.

The harbour quay 61 also includes various concrete structures 74, 76, 78, both to tie the harbour quay 60 to the surrounding area, and to protect the harbour quay 60 in use. The harbour quay 60 also includes a concrete drain 80.

In addition, the harbour quay 60 includes a cable 82 attached to a rear concrete anchor plate 84 to secure the structure 78 in position.

Referring to Figure 7, there is shown a harbour wall 90 formed from a plurality of wall sections 92 A to 92E. These wall sections 92 A to 92E are constructed adjacent an existing harbour or other solid object 94.

In contrast to the harbour wall 30 of Figure 3, the wall sections 92 A to 92E are located exactly side by side, with no steps there between, so that the harbour wall 90 has a straight front wall 96. In forming the harbour wall 90, from a plurality of tubes laid side by side and one on top of another, the tubes may be arranged in a common "brickwork" pattern, i.e with an upper tube straddling a join between two lower tubes, for increased strength.

Referring to Figure 8 there is shown a wall section 100, formed as described above, from a plurality of tubes 102, one on top of another, and filled with a filler material as described above.

The wall section 100 is formed in conjunction with piles 104 which are formed through the wall section 100, to form a completed structure such as a harbour wall. A concrete slab 106 is located on the top of the piles 104 and wall section 100.

Referring to Figure 9, there is shown a wall section 110, formed in the same manner as the wall section 100 of Figure 8, and including a pile 112 formed therethrough as illustrated, and with a concrete slab 114 on the top thereof.

Referring to Figure 10 there is shown a wall section 120 formed in the same manner as the wall section 100 of Figure 8, and formed behind a pile 122. Again a concrete slab 124 is formed on top of the wall section 120 and pile 122.

The method of the invention may be used to form any type of wall including walls for coffer dams, sea walls, piers, weirs, berms, snow walls, and the like.

The wall formed by the method of the invention may thereafter be provided with concrete slabs or the like on the top or front faces, for protection, with pipes therethrough for the provision of services, with shaped copings on top of harbour walls for wave reflection, and so on.

Claims

CLAIMS A method of constructing a wall element which is substantially rectangular in plan view and which comprises a main section and a front section, the method comprising the steps of:

(1) locating a tube of a flexible material divided by dividing walls of a flexible material into an array of compartments running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by the dividing walls has a honeycomb structure, with a first end of the tube on a base and a second end of the tube above the first end of the tube, the tube having a main section corresponding to the main section of the wall element and a front section corresponding to the front section of the wall element, wherein the compartments of the front section of the tube have a smaller cross-sectional size than the compartments of the main section of the tube; and

A method according to claim 1 wherein in step (1), the tube is supported in position using support means prior to being filled with the filler material. A method according to claim 1 or claim 2 wherein the tube and the dividing walls are made from a flexible material selected from the group consisting of a plastics material, a plastics laminate material, a metallic material, a woven or non- woven textile material, or a paper or cardboard material.

A method of constructing a wall or a section of a wall from a plurality of wall elements, each wall element being substantially rectangular in plan view and comprising a main section and a front section, each wall element being formed using a tube of a flexible material divided by dividing walls of a flexible material into an array of compartments running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by the dividing walls has a honeycomb structure, the tube having a main section corresponding to the main section of the wall element and a front section corresponding to the front section of the wall element, wherein the compartments of the front section of the tube have a smaller cross-sectional size than the compartments of the main section of the tube, which method comprises the steps of:

(e) locating a third tube on the second wall element in the same manner as the second tube is located on the first wall element, and so on, and filling substantially all of the compartments of the third and subsequent tubes with a filler material wherein some or all of the compartments of the front sections of the third and subsequent tubes are filled with a filler material which includes a binder, to form the third and subsequent wall elements, and thus to form the wall or wall section.

A method according to claim 4 wherein the first tube, the second tube and the subsequent tubes are all of substantially the same overall cross- sectional size, and the main sections and front sections of each of the tubes are of substantially the same overall cross-sectional size.

A method according to claim 4 wherein the second tube has a smaller overall cross-sectional size than the first tube, the third tube has a smaller overall cross-sectional size than the second tube and so on, so that, in use, the front section of each succeeding tube is stepped back from the front section of the underlying tube so that a wall or a wall section formed therefrom has a front side which slopes inwardly from the base to the top. A method according to any one of claims 4 to 6 wherein a sheet of a mesh material is located between each of the tubes located one on top of another to reinforce the wall or wall section formed therefrom.

A method according to any one of claims 4 to 7 wherein each tube is supported in position using support means prior to be filled with the filler material.

A method according to any one of claims 4 to 8 wherein each tube and the dividing walls thereof are made from a flexible material selected from the group consisting of a plastics material, a plastics laminate material, a metallic material, a woven or non- woven textile material, or a paper or cardboard material.

A method according to claim 9 wherein the flexible material is a plastics material.

A method of constructing a wall from a plurality of wall sections, each wall section being constructed according to the method of any one of claims 4 to 10, which comprises constructing a first wall section, constructing a second wall section abutting the first wall section, constructing a third wall section abutting the second wall section, and so on to form the wall.

A method according to claim 11 wherein adjacent sides of adjacent wall sections protrude into and interlock with each other to form the wall. A method according to claim 11 or claim 12 wherein the second wall section is stepped back from the first wall section, the third wall section is stepped back from the second wall section, and so on.

A method according to claim 11 or claim 12 wherein the wall sections are formed one adjacent to one another so that, in plan view, the wall has a straight front wall.

A method according to any one of claims 11 to 14 wherein a platform is constructed on top of the uppermost wall elements of the wall sections.

A wall or a section of a wall comprises a plurality of wall elements, each wall element being substantially rectangular in plan view and comprising a main section and a front section; a first wall element being located on a base, a second wall element being located on the first wall element with the front section of the second wall element on top of or overlapping the front section of the first wall element, a third wall element being located on the second wall element with the front section of the third wall element on top of or overlapping the front section of the first wall element and so on; each wall element being formed using a tube of a flexible material divided by dividing walls of a flexible material into an array of compartments running the length of the tube, the compartments being arranged in rows and columns so that the tube divided by the dividing walls has a honeycomb structure, the tube having a main section corresponding to the main section of the wall element and a front section corresponding to the front section of the wall element, wherein the compartments of the front section of the tube have a smaller cross- sectional size than the compartments of the main section of the tube; all of the compartments of the tubes being substantially filled with a filler material wherein some or all of the compartments of the front sections of the tubes are filled with a filler material which includes a binder.

A wall or a wall section according to claim 16 wherein the tube for the first wall element, the tube for the second wall element and the tubes for the subsequent wall elements are all of substantially the same overall cross-sectional size, and the main sections and front sections of each of the tubes are of substantially the same overall cross-sectional size.

A wall or wall section according to claim 16 wherein the tube for the second wall element has a smaller overall cross-sectional size than the tube for the first wall element, the tube for the third wall element has a smaller overall cross-sectional size than the tube for the second wall element and so on, so that, in use, the front section of each succeeding tube is stepped back from the front section of the underlying tube so that the wall or the wall section has a front side which slopes inwardly from the base to the top.

A wall or a wall section according to any one of claims 16 to 18 wherein a sheet of a mesh material is located between each of the tubes located one on top of another to reinforce the wall or wall section. A wall or a wall section according to any one of claims 16 to 19 wherein each tube and the dividing walls thereof are made from a flexible material selected from the group consisting of a plastics material, a plastics laminate material, a metallic material, a woven or non- woven textile material, or a paper or cardboard material.