WO2025008046A1 - Caisson et procédé de construction d'un caisson - Google Patents

Caisson et procédé de construction d'un caisson Download PDF

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Publication number
WO2025008046A1
WO2025008046A1 PCT/EP2023/068256 EP2023068256W WO2025008046A1 WO 2025008046 A1 WO2025008046 A1 WO 2025008046A1 EP 2023068256 W EP2023068256 W EP 2023068256W WO 2025008046 A1 WO2025008046 A1 WO 2025008046A1
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WO
WIPO (PCT)
Prior art keywords
wall
caisson
wall section
printing
longitudinal
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2023/068256
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English (en)
Inventor
Michael Holm
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Cobod International AS
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Cobod International AS
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Filing date
Publication date
Application filed by Cobod International AS filed Critical Cobod International AS
Priority to PCT/EP2023/068256 priority Critical patent/WO2025008046A1/fr
Publication of WO2025008046A1 publication Critical patent/WO2025008046A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D23/00—Caissons; Construction or placing of caissons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • B28B7/183—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article for building blocks or similar block-shaped objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B3/00—Engineering works in connection with control or use of streams, rivers, coasts, or other marine sites; Sealings or joints for engineering works in general
    • E02B3/04—Structures or apparatus for, or methods of, protecting banks, coasts, or harbours
    • E02B3/06—Moles; Piers; Quays; Quay walls; Groynes; Breakwaters ; Wave dissipating walls; Quay equipment
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/10—Deep foundations
    • E02D27/18—Foundations formed by making use of caissons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing

Definitions

  • the present invention relates to caissons and a method of constructing a caisson.
  • Caissons are used in a wide range of engineering projects involving the construction of foundations, bridges, harbors, offshore structures, and other structures that require stable and secure support.
  • caissons The primary function of caissons is to provide structural support and stability, especially in challenging marine conditions. They transfer the loads from superstructure, such as quays, piers, or container terminals, to the underlying seabed or bedrock. This reduces the risk of excessive settlement, erosion, or structural failure, ensuring the safety and longevity of marine infrastructure, while providing stable foundations and protection against water ingress, allowing for the efficient handling of maritime traffic, loading and unloading of cargo, and safe docking of vessels.
  • superstructure such as quays, piers, or container terminals
  • caissons are also used to create protective barriers, breakwaters, or retaining walls.
  • Caissons are large structures typically comprising a number of watertight chambers and are either pre-fabricated or constructed in situ. They are strategically positioned to withstand the forces exerted by waves, currents, and tides.
  • a caisson comprising a top side and a bottom side, the bottom side being opposite the top side and each of the top side and the bottom side extending in a longitudinal direction and in width direction; a side wall extending in a height direction between the top side and the bottom side and enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface, and where the side wall comprises a first longitudinal wall section extending in the longitudinal direction; and a first transverse wall section extending in the width direction; wherein each of the first longitudinal wall section and the first transverse wall section comprises at least one curved portion having a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and wherein the side wall is made of concrete by additive
  • each of the first longitudinal wall section and the first transverse wall section comprising at least one curved portion having a convex side as part of the outer surface of the side wall
  • the design of the caisson may offer improved force distribution and load bearing capabilities. Thereby allowing for less material use, and a cheaper and more environmentally friendly caisson. Further, the construction of the caisson by additive manufacturing may provide a faster and more optimized construction process, enabling design freedom of the caisson.
  • the longitudinal direction and width direction expands a first plane, which will typically be a horizontal plane during the intended use of the caisson.
  • the longitudinal direction and height direction expands a second plane, and the width direction and height direction expand a third plane, both typically be a vertical planes during the intended use of the caisson.
  • the curved portions may be arranged so that all of the side wall of the caisson will be in compression in a horizontal direction during it intended use. Thereby allowing for less material use in the design of the caisson while maintaining compressive strength.
  • Concrete is understood as a material comprising aggregate, water, and cement, where aggregate is a mineral material such as stone, gravel, or sand.
  • the concrete may further contain reinforcing materials such as fibers of steel, carbon, or polymer material, however reinforcing materials are not considered as part of the concrete itself.
  • the side wall encloses the inner volume so that the inner volume is fully enclosed.
  • the outer surface of the curved portions i.e., the convex side, may have a smooth or soft curved shape i.e., having rounded corners.
  • the outer surface of curved portions may have an edged curved shape i.e. having sharp or pointy corners.
  • the outer surface of curved portions may be a mixture of smooth curved and edged curved shapes.
  • the inner surface of the curved portions i.e., the concave side, is preferably circular or arced e.g., like a pointed arc, a semicircle or parabolic shape. This will aid in optimizing the force distribution within the curved portion of the side wall.
  • the curved portions may be oriented to align with the height direction, such that the curves are seen when viewing the curved portions in the first plane.
  • the curved portions may be oriented to align with the longitudinal or width direction, such that the curves is seen when viewing the curved portions in the second or thirds plane.
  • the curved portions may be oriented a vertical direction or in a horizontal direction, when considering the vertical direction and horizontal direction in terms of the intended use of the caisson. It should however be stressed that this is for explanation purposes only and the caisson may be oriented as seen fit by a user without limiting the scope of the invention. If the curved portions are oriented in a vertical direction, they will resemble column or pillar structures i.e., an upright cylindric or polygonal prism structure, when view from the outside surface of the caisson. It is currently considered advantageously to have the curved portions oriented in a vertical direction.
  • the caisson may be a minimum of 10 m long in the longitudinal direction.
  • the caisson may be a minimum of 4 m wide in the width direction.
  • the caisson may be a minimum of 4 m heigh in the height direction.
  • the height of the side wall may be constant or vary.
  • the caisson may be constructed using a concrete having an compressive strength of 1 MPa, 2 MPa, 3 MPa, 4 MPa or 5 MPa.
  • Additive manufacturing is the process of extruding or printing out a material layer by layer, this process is also known as 3D printing. Larger concrete additive manufacturing or 3D printing systems are well known to the skilled person and will hence not be explained more in detail here.
  • an inner support wall extends between wall sections of the side wall through the inner volume, thereby dividing the inner volume into at least two separate volumes.
  • the inner support wall may increase the strength of the side wall by acting as a reinforcing structure between the wall sections which it extends between to transfer some of the external load on the side wall.
  • the inner support wall may be a cast or precast structure, of either concrete or another material.
  • the inner support wall may be constructed by concrete additive manufacturing, either printed simultaneously with the side wall, i.e., as part of the same print, or independently of the side wall, e.g., before or after printing the side wall.
  • the inner support wall may be transversal and/or perpendicular to the longitudinal direction.
  • the inner support wall may be transversal and/or perpendicular to the width direction.
  • the inner support wall may have a constant or varying height, i.e., extension between the top and bottom side.
  • the inner support wall may be lower, equal to, or higher than the side wall.
  • the caisson may further comprise a core compartment within the inner volume, where the core compartment is defined by a core wall which encloses the core compartment.
  • the core wall may extend in a substantially parallel trajectory of the side wall or have a different shape compared to the side wall, when viewing the side wall and core wall in the first plane.
  • the core wall does not directly connect to the side wall but may be indirectly connected to the side wall by other walls, such as an inner support wall.
  • the core wall may e.g., be square, rectangular, or circular when viewed the first plane.
  • the caisson may comprise a plurality of core compartments, each with their own core wall. A plurality of core compartments may be arranged within each other, such that one core compartment is enclosed by another core compartment, etc., all being enclosed within the side wall.
  • the side wall further comprises a second transverse wall section, and a second longitudinal wall section, where each of the second transverse wall section and the second longitudinal wall section comprising at least one curved portion having a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and where the second longitudinal wall section extends in the longitudinal direction and the first and second transverse wall sections extend between the first and second longitudinal wall sections.
  • the second transverse wall sections and second longitudinal wall section, together with the first transverse wall sections and first longitudinal wall section will define a caisson having a shape with an overall appearance of a square or rectangular box.
  • the inner support wall extends between the first and second longitudinal wall sections.
  • the inner support wall may increase the strength of the longitudinal wall sections by acting as a reinforcing structure between the longitudinal wall sections by transferring some of the external load from forces acting on the longitudinal wall sections.
  • the inner support wall extends between first and second transversal wall sections.
  • the inner support wall may increase the strength of the transversal wall sections by acting as a reinforcing structure between the transversal wall sections by transferring some of the external load from forces acting on the transversal wall sections.
  • a plurality of inner support walls extends between the first and second transversal wall sections. Thereby may the strength of the transversal wall sections be increasing even further.
  • a plurality of inner support walls extends between the first and second longitudinal wall sections.
  • the plurality of inner support walls may increase the strength of the side walls by acting as a reinforcing structure between the wall sections which they extends between by transferring some of the load from the external forces acting on the side wall.
  • Inner support walls may extend in several directions within the inner volume for example forming a lattice or a star shape.
  • the caisson comprises a plurality of curved portions connected by inner support walls, and where the curved portions together of the side wall of the caisson enclosing the inner volume such that it is giving the caisson the overall shape of a flower.
  • a caisson is well suited for withstanding external horizontal loads, such as water pressure if the caisson is a floating caisson or earth pressure if the caisson is used on-shore or resting on a sea bed.
  • An interior circular wall surrounding may be interconnecting the inner support walls of the caisson to provide additional strength and stiffness by hindering deflection of the inner support walls and possibly also a bottom plate.
  • the inner support walls may be provided with local reinforcement where they intersect or meets each other or the side wall to allow a distribution of pressure.
  • each of the first longitudinal wall section, second longitudinal wall section, first transverse wall section and second transverse wall section comprises a plurality of the curved portions.
  • a plurality of curved portions may distribute loads more efficiently and provide a stronger caisson.
  • the plurality of curved portions may be similar in size and curvature/shape. Alternatively, the plurality of curved portions may be different to each other in size and curvature/shape. Some of the plurality of curved portions may be similar in size and curvature/shape, while others are different to each other in size and curvature/shape.
  • Inner walls are preferably provided where two or more curved portions meet each other so that compression forces on the curved portions can be transferred.
  • an inner wall extends from where two curved portions of one wall section meet two curved portions of another opposite one wall section, for extending from one longitudinal wall section to another longitudinal wall section.
  • the first and second transverse wall sections each have an overall curved shape curving outwards away from each other in the longitudinal direction. Consequently, the caisson may be strengthened further and able to take more external load along the longitudinal direction.
  • the outwards curving shaped of the transverse wall sections may be considered as the curved portion of the transverse wall sections.
  • outwards curving shaped of the trans- verse wall sections may be supplemental to the curved portions of the transverse wall sections.
  • each transverse wall sections has a curved shape with a convex side being part of the outer surface of the side wall.
  • the plurality of curved portions of the first transverse wall section is arranged in a first pattern of protrusions
  • the plurality of curved portions of the second transverse wall section is arranged in a second pattern of protrusions, and where the first pattern and the second pattern are invers of each other. Consequently providing an interlocking design which may provide stability, strength, and ease of connecting two or more caissons together along the longitudinal direction.
  • the first transverse wall section of a first caisson will be configured to interlock with the second transverse wall section of a second caisson.
  • An interlocking design may enable a close and precise connection between caissons, which in turn may increase the stretch of the connection and make it less likely to slip or disconnect over time.
  • An interlocking design may leave one or more spaces between the two caissons, and such a space may be filled with concrete.
  • the outer surface of the side wall of the first transverse wall section may have a profile when seen from above, which is inverse of the profile of the second transverse wall section.
  • the plurality of curved portions of the first transverse wall section protrudes and recesses in a pattern making their outer shape inverse of the outer shape of the pattern of the plurality of curved portions of the second transverse wall section, so the first transverse wall section could fit together with second transverse wall section, should they be brought into contact.
  • At least one inner support wall comprises a recess or an opening.
  • a recess or opening in the inner support wall allows for material savings of the construction.
  • the inner support wall may comprise a plurality of recesses or openings, or a combination of recesses and openings. Openings may potentially have a positive effect on the compressive strength of the inner support walls and/or may allow material used for weighing the caisson down to travel between separate volumes, cavities, and/or compartments of the inner volume.
  • a bottom plate close off the bottom side.
  • the bottom plate may provide a reinforced bottom side of the caisson.
  • the bottom plate may function as a foundation for printing the side wall and possibly inner wall(s) of the caisson.
  • the bottom plate may be of cast and/or reinforced concrete. Alternatively, the bottom plate may be constructed by additive manufacturing prior to printing the side wall.
  • the bottom plate may have a strength generally higher than the side wall and possible inner walls of the caisson. Higher strength may mean capability of taking a higher load and/or more mechanical stress, and/or have a higher hardness, and/or a higher tensile strength.
  • the bottom plate may be an integral part of the caisson.
  • Inner walls, flanges, beams or the like extending from the side wall may be configured for transferring loads to the bottom plate.
  • the top side of the caisson is open, but may possibly be closed off by a structure not forming an integral part of the caisson, for example as a part of the construction of a pier or dock.
  • the caisson may comprise a top plate closing off the top side.
  • Such a top plate may be constructed by a stronger concrete than other parts of the caisson.
  • the top plate may be a printed or cast concrete.
  • the side wall comprises at least X% concrete, measured by weight or volume.
  • the caisson may be made completely without the use of rebars.
  • the caisson may be made completely without the use of steel reinforcement.
  • the caisson may be made completely without the use of any reinforcement.
  • a system comprising a caisson according to the first aspect and a facing wall which shields the outer surface of at least a portion of the side wall. Consequently, a protective layer for a portion of the outer surface of the caisson is provided.
  • the facing wall may be constructed using a stronger concrete than the side wall of the caisson, and/or a stronger material, such as metal or metal alloy.
  • stronger material or stringer concrete is meant a material or concrete capable of take a higher compressive load and/or more mechanical stress, and/or have a higher hardness, and/or a higher tensile strength.
  • the facing wall may e.g., increase the lifetime of the caisson by enable it to better handle collision with ships and boats.
  • the facing wall may be mounted on the portion of the side wall such that a number of cavities are present between the facing wall and the side wall.
  • the facing wall may comprise a number of openings.
  • the number of openings may comprise a number of different sized openings.
  • the number of openings may allow wildlife to enter into a number of cavities between the facing wall and the side wall.
  • the facing wall may have the same height as the caisson or it may higher to i.e., extent over the top side of the caisson.
  • the facing wall may comprise a top portion located adjacent the top side of the caisson in a mounted state.
  • the top portion may have a larger thickness than the remaining facing wall.
  • the top portion may be made of a reinforced concrete comprising rebars, fibres, and/or other reinforcing material.
  • the top portion may be constructed using a stronger material, e.g., a stronger concrete than the side wall and/or the rest of the facing wall.
  • the top portion may comprise one or more cavities configured for being filled with concrete, stones, gravel or the like.
  • the facing wall shields all of the first longitudinal wall section, thereby providing protection for the first longitudinal wall section.
  • the facing wall is constructed by additive manufacturing. By also construction the facing wall by additive manufacturing, the construction process may be fast and cheap.
  • the facing wall may be printed after the construction of the caisson or simultaneously with printing the caisson.
  • a system comprising a first and a second caisson according to the first aspect; where the first caisson and the second caisson are arranged adjacent to one another with a wall section of the first caisson abutting a wall section of the second caisson, and where a gap between the wall section of the first caisson and the wall section of the second caisson is filled with concrete.
  • the wall sections of the side wall of the caissons may be configured to interlock the with each other to provide a strong and durable connection after the gap between the wall sections is filled with concrete.
  • the gap is filled with concrete to connect the first and second caisson in a sealed and strong connection, and to limit or stop water ingress between the caissons.
  • a method of constructing a caisson comprising a top side, a bottom side, and a side wall extending between the top side and the bottom side, the side wall enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface; the method comprising the steps: printing a bottom layer of the side wall by extruding concrete from a printing head along a side wall printing path comprising a first longitudinal wall section extending in a longitudinal direction, and a first transverse wall section extending in a width direction; printing a plurality of subsequent layers of the side wall on top of the bottom layer and on top of each other; wherein each of the first longitudinal wall section and the first transverse wall section of the side wall printing path comprises at least one curved portion forming a convex side and a concave side of the side wall, where the convex side of each curved portion is part of the outer surface of the side wall
  • the caisson is constructed by providing an additive manufacturing system comprising a printing head configured to print concrete; providing concrete to the printing head, the concrete comprising at least aggregate, water and a binder; and printing the caisson according the above disclosed method.
  • the bottom side of the bottom layer may define the bottom side of the caisson.
  • the method further comprises printing an inner support wall by extruding concrete from a printing head along an inner support wall printing path extending between wall sections of the side wall through the inner volume. Thereby dividing the inner volume into at least two separate cavities by the inner support wall to produce a caisson having an overall higher strength. This will especially increase the compressive strength of the caisson.
  • the side wall printing path further comprises a second transverse wall section and a second longitudinal wall section along, where each of the second transverse wall section and the second longitudinal wall section of the side wall printing path comprises at least one curved portion forming a convex side and a concave side, where the convex side of each curved portion is part of the out- er surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and where the second longitudinal wall section extends in the longitudinal direction and the first and second transverse wall sections extend between the first and second longitudinal wall sections.
  • the method further comprises printing a plurality of inner support walls by extruding concrete from a printing head along a plurality of inner support wall printing paths extending between the first and second longitudinal wall sections.
  • the plurality of inner support wall may increase the strength of the side wall and thereby the overall strength of the caisson.
  • the method further comprises printing one or more inner support walls by extruding concrete from a printing head along one or more printing paths extending between the first and second transversal wall sections.
  • the inner support walls may increase the strength of the side wall and thereby the overall strength of the caisson.
  • the first and second transverse wall sections of the printing path each have an overall curved shape curving outwards away from each other in the longitudinal direction. Consequently, the caisson may be strengthened further and able to take more external load along the longitudinal direction.
  • each of the first longitudinal wall section, second longitudinal wall section, first transverse wall section and second transverse wall section comprises a plurality of the curved portions.
  • a plurality of curved portions may distribute loads more efficiently and provide a stronger caisson.
  • the plurality of curved portions of the first transverse wall section is arranged in a first pattern of protrusions
  • the plurality of curved portions of the second transverse wall section is arranged in a second pattern of protrusions, and where the first pattern and the second pattern are invers of each other. Consequently, providing an interlocking design which may provide stability, strength, and ease if connecting two or more caissons together along the longitudinal direction.
  • the method further comprises printing a bottom plate prior to printing the bottom layer of the side wall, and in the step of printing the bottom layer of the side wall, printing the bottom layer of concrete on top of the bottom plate.
  • the bottom plate is advantageously completely closed to close off the bottom side of the caisson.
  • the caisson may be able to float on water or rest on soft ground or seabed with a reduced risk of setting.
  • the bottom plate may also contribute to distributing forces, for example if the caisson rests on inhomogeneous ground or seabed.
  • Fig. 1 shows an elevated perspective view of a caisson as known in the prior art.
  • Fig. 2 shows an elevated perspective view of an embodiment of a caisson of the invention.
  • Fig. 3 shows an elevated perspective view of an embodiment of a caisson of the invention.
  • Fig. 4 shows an elevated perspective view of an embodiment of a caisson of the invention.
  • Fig. 5 shows a lowered perspective view of the embodiment according to fig.
  • Fig. 6 shows a top view of the embodiment according to fig. 4 and 5.
  • Fig. 7 shows an elevated perspective view of an embodiment of a system of a caisson and a facing wall.
  • Fig. 8 shows an elevated perspective view of an embodiment of a system of a caisson, a top plate, and a facing wall.
  • Fig. 9 shows an elevated perspective view of a system of two caissons in engagement, each caisson engaging with a facing wall.
  • Fig. 10 shows an elevated perspective view of an embodiment of a caisson of the invention.
  • Fig. 11 shows a top view of the embodiment of fig. 10.
  • Fig. 12 shows a flow diagram of an embodiment of a method for constructing a caisson.
  • Fig. 13 shows an embodiment of an additive manufacturing system.
  • Fig. 14 shows a front view of an embodiment of a caisson of the invention in its use state.
  • Fig. 15 shows a front view of an embodiment of a caisson of the invention in its use state.
  • Figure 1 shows a classic caisson 1 as known in the prior art
  • Figure 2 shows an embodiment of a caisson 1 according to the invention
  • the Both of these caissons comprise a top side 2 and bottom side 3.
  • the bottom side 3 is opposite of the top side 2.
  • a side wall 4 extends between the top side 2 and the bottom side 3 in a height direction D3 and has an inner surface 41 and an outer surface 42.
  • the inner surface 41 is opposite the outer surface 42.
  • the side wall 4 fully encloses an inner volume, which is further delimited by the top side 2 and the bottom side 3.
  • the side wall 4 comprises longitudinal wall sections 51 extending in a longitudinal direction DI, and transverse wall sections 52 extending in a width direction D2 being transverse to the longitudinal direction DI.
  • the caisson in Figure 1 has only straight walls, but in the caisson in Figure 2 the longitudinal wall sections 51 comprises a number of curved portions 6 having a convex side 61 and a concave side 62.
  • the convex side 61 of each curved portion 6 is part of the outer surface 42 of the side wall and each concave side 62 of each curved section is part of the inner surface 41 of the side wall 4.
  • the transverse wall sections 52 in Figure 2 each have an overall curved shape curving outwards away from each other in the longitudinal direction DI, and the transverse wall sections 52 are regarded as curved portions 6 having a convex side 61 and a concave side 62. Where the convex side 61 is part of the outer surface 42 of the side wall and the concave side 62 is part of the inner surface 41 of the side wall 4.
  • the side wall 4 is made of concrete by additive manufacturing.
  • additive manufacturing of concrete is a well-established field of technology to a person skilled in the art, the specific technique will not be explained more in detail.
  • Both caissons further comprise inner support walls 7 extending between wall sections of the side wall 4 and through the inner volume.
  • a number of the inner support walls extend in the width direction D2 and in the embodiment in Figure 2 these inner support walls extend between points where the curved portions 6 of the longitudinal wall sections 51 of the side wall 4 meet with one another.
  • there is also a number of inner support walls 7 extending in the longitudinal direction DI and the embodiment in Figure 2 there is further a number inner support walls 7 extending transversely between the transverse inner support walls 7, the longitudinal inner support walls 7, and the transverse wall section 52 of the side wall 4.
  • the inner support walls 7 are dividing the inner volume into multiple separate volumes, which may be filled with stones, gravel, dirt, or the like in order to ballast the caisson. With the embodiment in Figure 2, it is currently considered advantageously to make the inner support walls 7 of concrete by additive manufacturing.
  • the caisson shown in Figure 2 can be built by additive manufacturing in about 1 month by approximately 15 workers.
  • construction of a traditional caisson as the one shown in Figure 1 which is typically built in a floating dock and contains of a high amount of steel reinforcement, which concrete is cast around, takes up to 2 months and easily requires 50-100 manual workers.
  • Figure 3 shows a caisson, which is similar to the embodiment of figure 2, the difference being that all of the inner support walls 7 comprise openings 8.
  • the openings 8 are included in the design to save material and not have any significant influence on the compressive strength of the inner support walls, which should preferably be at least 2 MPa compressive pressure.
  • the openings are here drop-shaped as this increases the ease of construction when using additive manufacturing, however the opening may have any suitable geometry.
  • FIG 4-6 shows an alternative embodiment of a caisson 1 in different views.
  • the transverse wall sections 52 of the caisson of figure 4 comprises a plurality of curved portions 6 having a convex side 61 and a concave side 62.
  • the transverse wall section 52 at a first end of the caisson comprises two curved portions 6, and the transverse wall section at a second end of the caisson comprises three curved portions 6.
  • the curved portions 6 of the first transverse wall section is arranged in a first pattern of protrusions
  • the curved portions 6 of the second transverse wall section is arranged in a second pattern of protrusions such that the first pattern and the second pattern each define a profile in the outer surface of the side wall 4.
  • These profiles are invers of each other and designed to interlock, thereby allowing caissons arranged adjacent to each other to connect to each other when aligning the transverse wall section 52 of a first end of a first caisson to the transverse wall section at a second end of another caisson, etc.
  • the caisson 1 comprises a bottom plate 9 to close off the bottom side 3.
  • the bottom plate 9 may e.g., be a precast reinforced concrete structure, on which the side wall 4 and inner support walls 7 are printed.
  • Figure 7 shows a system 200 comprising a caisson according to figure 4-6 and a facing wall 10, which shields the outer surface of one of the longitudinal wall sections 51 of the side wall 4.
  • the facing wall 10 works as a protective layer for the caisson 1 and may be constructed by additive manufacturing, either simultaneously with or after the construction of the caisson.
  • a cavity 101 in the top of the facing wall 10 is designed to be filled with concrete to take a high compressive load and/or mechanical stress, as the top part of the facing wall 10 is designed to be point of contact with e.g., ships and boats, when the caisson is used in a maritime environment.
  • the facing wall 10 further comprises a number of openings 8 which may serve as entrances into a volume 102 between the facing wall 10 and the caisson 1, e.g., to allowing wild life to seek shelter within the volume.
  • Figure 8 shows the system 200 according to figure 7, with the addition of a top plate 11 placed or casted on top of the caisson 1 and extending into the top cavity 101 of the facing wall 10.
  • the top plate 11 will advantageously be made of reinforced concrete. It is, however, also possible to file the volume here shown as a top plate with rocks or gravel.
  • Figure 9 shows a system 300 comprising two caissons according to figure 4-6.
  • the first caisson 1 and the second caisson 1 are arranged adjacent to one another with a respective one of their transverse wall sections 52 abutting each other, so that the transverse wall section 52 at a first end of the first caisson 1 and the transverse wall section 52 at a second end of the second caisson 1 interlock with each other.
  • a small gap 12 (as seen in the zoomed view).
  • the gap may be filled with concrete to connect the caissons.
  • FIG. 10 and 11 shows an alternative embodiment of the caisson 1'.
  • the caisson 1' has curved portions 6 arranged in a flower shape, and the curved portions
  • the curved portions 6 have a smooth curved shape, however they may also be sharp, pointy, having rounded corners, or a combination.
  • the curved portions shown in the embodiment of figure 10 and 11 is of equal size, but embodiment where the size of the curved portions 6 vary is comprised within the scope of the invention. This applies to all embodiment independent of the overall shape, i.e. including caissons having a rectangular shape as in figures 2-9.
  • the caisson 1' further comprises an interior curved wall 6' in the shape of a circle, to provide additional stability.
  • the side wall 4 and the inner support walls 7 may be provided with local reinforcement where they meet and intersect to be able to take up forces originating from exterior water pressure.
  • the bottom plate 9 of the caisson 1' allows it to float.
  • the inner support walls 7, the curved portions 6, and the interior curved wall 6' may contribute to supporting the bottom plate 9 against water pressure from below.
  • the interior spaces between the curved portions 6 and the inner support walls 7 may be filled, for example with rocks, gravel, or water.
  • FIG 12 showings the steps a flow diagram of an embodiment of a method for constructing a caisson comprising a top side, a bottom side, and a side wall extending between the top side and the bottom side, the side wall enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface.
  • step 1001 printing a bottom layer of the side wall by extruding concrete from a printing head along a side wall printing path comprising a first longitudinal wall section extending in a longitudinal direction, and a first transverse wall section extending in a width direction.
  • Each of the first longitudinal wall section and the first transverse wall section of the side wall printing path comprises at least one curved portion forming a convex side and a concave side of the side wall, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall.
  • step 1002 printing a plurality of subsequent layers of the side wall on top of the bottom layer and on top of each other.
  • step 1003 printing an inner support wall by extruding concrete from a printing head along an inner support wall printing path extending between wall sections of the side wall through the inner volume.
  • step 1004 printing a facing wall in front of all of the first longitudinal wall section.
  • the method may optionally comprise one or more of the following sub steps: Printing a second transverse wall section and a second longitudinal wall section of the side wall printing path, each comprising at least one curved portion forming a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and where the second longitudinal wall section extends in the longitudinal direction and the first and second transverse wall sections extend between the first and second longitudinal wall sections.
  • Figure 13 shows an embodiment of an additive manufacturing system 2000 with a printing unit 2001 mounted on a gantry system 2002 configured for moving the printing unit in a three-dimensional space defined by axes X, Y, and Z corresponding to the longitudinal direction DI, width direction D2 and height D3.
  • the printing unit 2001 is mounted to be moveable along a first horizontal beam 2003 in a horizontal direction along the X-axis
  • the first horizontal beam is mounted to be moveable along a set of second horizontal beams 2004 in a horizontal direction along the Y-axis
  • the second set of horizontal beams are mounted to be moveable along four uprights 2005 in a vertical direction along the Z-axis.
  • the position and extend of the four uprights 2005 thus delimit the space in which the printing unit 2001 can move.
  • the movement of the beams 2003, 2004 is here achieved by the use of motors built into attachments blocks 2006 and the printing unit 2001 is moved by a chain drive (not visible) driven by a motor built into attachments blocks 2006 of the first horizontal beam.
  • Each of the four uprights 2005 of the gantry system 2002 rest on a caisson 1"7 provided on the surface 5000 on which a construction is to be printed, and a first wall of a caisson 1 has been printed.
  • the surface 5000 may for example be a ground surface, a foundation, or an upper surface of an existing construction, such a bottom plate 9.
  • a printing material supply facility 3000 is shown, and a tubing system 4000 connects the printing material supply facility to the printing unit 2001, serving as a printing material supply line.
  • the printing material supply facility 3000 may comprise a mixing unit and/or a buffer unit for receiving printing material produced elsewhere.
  • the printing material is concrete consisting of cement, aggregate and water and may be made in the printing material supply facility or supplied from an external manufacturing site. It is also possible to modify a material supplied from an external manufacturing site in the printing material supply facility, for example by admixing one or more additives, aggregates, or fibers.
  • a material pump 3001 is used for pushing the printing material from the printing material supply facility 3000 through the tubing system 4000 to the printing unit 2001.
  • the material pump is integrated in the printing material supply facility 3000, but it could also be a separate unit.
  • the material pump 3001 could be replaced by or supplemented with a material pump arranged at or on the gantry system 2002, and that such a material pump might be a suction pump.
  • a piston pump which is well suited for moving high viscosity material. This applies regardless of how other parts of the additive manufacturing system 2000 are embodied.
  • the tubing system 4000 is here composed of flexible tubes allowing the tubing system to follow the movement of the gantry system 2002 and the printing unit 2001 so that a continuous and reliable supply of printing material is ensured.
  • the tubing system may also comprise pipes.
  • One or more additive supply lines may be integrated in the tubing system 4000.
  • a control unit 3002 for controlling the supply of printing material to the printing unit 2001 is built into the printing material supply facility.
  • the control unit 3002 could alternative be located elsewhere, including on or at the printing unit 2001 or on or at the gantry system 2002.
  • FIG 14 shows an embodiment of a caisson 1 of the invention in its use state, where the caisson 1 will typically be submerged partially or fully under water when used in a marine environment.
  • the top side 2 of the caisson 1 is below the sea surface 14 and its bottom side 3 rests on the sea bed 13. Even though it is not shown it is possible that a part of the caisson would be above the sea surface 14, depending on the depth of the water and influence of tides.
  • Figure 15 shows the system 200 of a caisson 1, a facing wall 10 and a top plate 11.
  • the top plate 11 will typically be placed above the level of the sea surface 14, when the caisson is used in a harbor setting, but could be fully submerged if intended as foundation or the like or marine installations.
  • any method or any step of method may be seen also as an apparatus description, any apparatus embodiment, aspect, or part of aspect or part of embodiment may be seen as a method description, and all may be combined in any possible way down to the smallest detail.
  • Any detailed description should be interpreted in its broadest outline as a general summary description, and please note that any embodiment or part of embodiment as well as any method or part of method could be combined in any way. All examples herein should be seen as part of the general description and therefore possible to combine in any way in general terms.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
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  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mining & Mineral Resources (AREA)
  • Paleontology (AREA)
  • Ocean & Marine Engineering (AREA)
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Abstract

L'invention concerne un caisson qui comprend un côté supérieur et un côté inférieur, le côté inférieur étant opposé au côté supérieur et chacun du côté supérieur et du côté inférieur s'étendant dans une direction longitudinale et dans la direction de la largeur. Une paroi latérale s'étend dans une direction de hauteur entre le côté supérieur et le côté inférieur et renferme un volume interne, qui est en outre délimité par le côté supérieur et le côté inférieur, la paroi latérale ayant une surface interne faisant face au volume interne et une surface externe opposée à la surface interne, et la paroi latérale comprenant. Une première section de paroi longitudinale s'étend dans la direction longitudinale et une première section de paroi transversale s'étend dans la direction de la largeur. Chacune de la première section de paroi longitudinale et de la première section de paroi transversale comprend au moins une partie incurvée ayant un côté convexe et un côté concave, le côté convexe de chaque partie incurvée faisant partie de la surface externe de la paroi latérale et le côté concave de chaque partie incurvée faisant partie de la surface interne de la paroi latérale, et la paroi latérale étant constituée de béton par fabrication additive.
PCT/EP2023/068256 2023-07-03 2023-07-03 Caisson et procédé de construction d'un caisson Pending WO2025008046A1 (fr)

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PCT/EP2023/068256 WO2025008046A1 (fr) 2023-07-03 2023-07-03 Caisson et procédé de construction d'un caisson

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PCT/EP2023/068256 WO2025008046A1 (fr) 2023-07-03 2023-07-03 Caisson et procédé de construction d'un caisson

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Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2705403A (en) * 1950-05-19 1955-04-05 Ebert Philipp Caisson
GB2121854A (en) * 1982-06-08 1984-01-04 Taisei Corp Marine structure constructing method
KR100982970B1 (ko) * 2010-03-25 2010-09-17 에스케이건설 주식회사 태극 요철형 케이슨을 이용한 방파제 시공방법
CN203808089U (zh) * 2014-03-19 2014-09-03 中交第一航务工程勘察设计院有限公司 弧面矩形沉箱结构
KR101694524B1 (ko) * 2016-08-19 2017-01-10 이인옥 항만구조물의 케이슨
EP3276086A1 (fr) * 2015-03-27 2018-01-31 Drace Infraestructuras, S.A. Fondation par gravité pour l'installation d'aérogénérateurs au large des côtes
CN209162871U (zh) * 2018-10-26 2019-07-26 中铁第四勘察设计院集团有限公司 一种适用于深水软土地区的悬索桥锚碇复合基础
WO2020176262A2 (fr) * 2019-02-13 2020-09-03 Jason Cotrell Ancres ventouses et leurs procédés de fabrication
CN112372791A (zh) * 2020-11-20 2021-02-19 上海言诺建筑材料有限公司 一种沉井3d打印机

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2705403A (en) * 1950-05-19 1955-04-05 Ebert Philipp Caisson
GB2121854A (en) * 1982-06-08 1984-01-04 Taisei Corp Marine structure constructing method
KR100982970B1 (ko) * 2010-03-25 2010-09-17 에스케이건설 주식회사 태극 요철형 케이슨을 이용한 방파제 시공방법
CN203808089U (zh) * 2014-03-19 2014-09-03 中交第一航务工程勘察设计院有限公司 弧面矩形沉箱结构
EP3276086A1 (fr) * 2015-03-27 2018-01-31 Drace Infraestructuras, S.A. Fondation par gravité pour l'installation d'aérogénérateurs au large des côtes
KR101694524B1 (ko) * 2016-08-19 2017-01-10 이인옥 항만구조물의 케이슨
CN209162871U (zh) * 2018-10-26 2019-07-26 中铁第四勘察设计院集团有限公司 一种适用于深水软土地区的悬索桥锚碇复合基础
WO2020176262A2 (fr) * 2019-02-13 2020-09-03 Jason Cotrell Ancres ventouses et leurs procédés de fabrication
CN112372791A (zh) * 2020-11-20 2021-02-19 上海言诺建筑材料有限公司 一种沉井3d打印机

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