CONSTRUCTION APPARATUS AND AN ASSOCIATED METHOD

FIELD OF THE IN VENTION

The present invention relates to a construction apparatus and an associated method Preferred embodiments of the invention find application, although not exclusively, in construction contexts such as the erection of concrete structures using methods involving formwork.

RACKGROUND The discussion of the prior art within this specification is not, and should not be taken as, an admission of the extent of common general knowledge in the field of the invention. Rather, the discussion of the prior art is provided merely to assist the addressee to understand the invention and is included without prejudice.

Workers at construction sites often utilise heavy, bulky and expensive machinery during the construction process. Some types of construction, such as the erection of formwork and the pouring of concrete into the formwork, for example, require the repeated usage of combinations of heavy machinery in a number of time consuming steps. Those skilled in the art will appreciate that the construction industry can be extremely competitive and cost sensitive. Hence it would be advantageous to provide apparatus for use on construction sites that facilitates the alternation between various machinery modes, that reduces the bulk and footprint of such machinery and which assists to minimise the costs associated with the construction process.

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a construction apparatus including: a tower; a turret adapted for disposition upon said tower; a crane assembly disposed on said turret; and a concrete placement boom disposed on said turret,

whereby, in use, a torque exerted On the tower by the concrete placement boom at least partially counterbalances a torque exerted on the tower by the crane assembly.

Preferably the crane assembly defines a crane proximal end and a crane distal end, the crane proximal end being disposed on the turret such that the crane distal end projects from the tower in a first direction, and the concrete placement boom defining a boom proximal end and a boom distal end, the boom proximal end being disposed on the turret such that the boom distal end projects from the tower in a second direction substantially opposite to the first direction.

Ia the preferred embodiment an angular disposition of the concrete placement boom relative to the turret is selectively adjustable. Hence, the amount of torque exerted on the tower by the concrete placement boom is selectively adjustable by means of adjusting the angular disposition of the concrete placement boom.

Preferably the turret is rotatably disposed On the tower such that rotation of the turret effects rotation of the crane assembly and of the concrete placement boom.

In the preferred embodiment the crane assembly is a knuckled luffing crane assembly having a plurality of hingcdly interconnected crane members including a proximal crane member defining the crane proximal end. In this embodiment the proximal crane member includes a tension member attached to first and second ends of the proximal crane member. This tension member extends substantially parallel to an elongate dimension of the proximal crane member.

Preferably the plurality of hingedly interconnected crane members includes a distal crane member defining the crane distal end, a leading sheave and a trailing sheave being disposed on the crane distal end for supporting a load carrying cable, the cable being threaded intermediate the leading sheave and the trailing sheave so as to depend from either of the sheaves dependent upon an orientation of the distal crane member relative to gravity.

In the preferred embodiment the concrete placement boom includes a plurality of hingedly interconnected boom members including a proximal boom member defining the boom proximal end. Preferably the proximal boom member is at least 20%, or more preferably at least 60%, longer than a longest length of the remaining boom members.

Preferably the concrete placement boom has a range of movement sufficient to define a line of declination extending between the boom proximal end and the boom distal end that is at least 10°, or more preferably at least 20º, from the horizontal.

For disassembly of the preferred embodiment each of the following modular components are separately removable: the concrete placement boom; the crane assembly with the exception of a proximal portion of the proximal crane member; and the turret and the proximal portion of the proximal crane member.

In alternative preferred embodiments the crane assembly takes on other forms, for example that of a boom crane assembly or a fixed jib crane assembly,

Preferably the crane assembly and the concrete placement boom are separately pivotable about a common axis of rotation.

In a second aspect the invention provides a turret adapted for disposition upon a tower, said turret including a crane assembly mounting means and a concrete placement boom mounting means.

Preferably the crane assembly mounting means and the concrete placement boom mounting means comprise a pair of apertures adapted to house a corresponding pair of outer sleeves for mounting of one of the crane assembly or the concrete placement boom, said outer sleeves being adapted to receive and an inner member for mounting of the other of the crane assembly or the concrete placement boom.

In the preferred embodiment the outer sleeves are disposed at, or adjacent to, opposite ends of the inner member. Preferably the inner member and the pair of outer sleeves are cylindrical and the outer sleeves are concentric with the inner member. More preferably a radially inner surface of each of the sleeves is in contact with a radially outer surface of the inner member.

During disassembly of a preferred embodiment using one of the turrets as described above, one of the crane assembly or the concrete placement boom is detachable from the turret whilst the other of the crane assembly or the concrete placement boom remains attached to the turret.

Preferably the inner member is hollow and a concrete supply pipe is threadable through the hollow inner member.

The preferred embodiment includes a pair of retaining members, each being fastenable into abutment with one of the sleeves and with one end of the inner member.

In a third aspect the present invention provides a construction apparatus including; a tower; a Turret adapted for disposition upon said tower; a crane assembly disposed on said turret; a concrete placement boom disposed on said turret; and control means configured to permit separate operation of one of the crane assembly or the concrete placement boom relative to the other of the crane assembly or the concrete placement boom.

In a fourth aspect the invention provides a construction method including: providing a construction apparatus having a tower, a turret rotatably disposed upon said tower, a crane assembly extending from said turret in a first direction and a concrete placement boom extending from said turret in a second direction opposed to the first direction, said concrete placement boom supporting a concrete supply pipe defining an outlet;

using the crane assembly to position formwork so as Io define at least one concrete receptacle; rotating the turret and manoeuvring the concrete placement boom such that the outlet feeds into the concrete receptacle; and pumping concrete through the pipe, out of the outlet, and into the concrete receptacle.

In another aspect the invention provides a structure constructed using the method described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a side view of the preferred embodiment of the invention with both the crane assembly and the concrete placement boom in retracted positions;

Figure 2 is a side view of the preferred embodiment of the invention with the crane assembly extended upwardly so as to suspend a load close to the base of the tower, Figure 3 is a side view of the preferred embodiment of title invention with the crane assembly extended horizontally so as to suspend a load at a position remote from the base of the tower;

Figure 4 is a side view of the preferred embodiment of the invention with the concrete placement boom extended horizontally so as to suspend a concrete supply pipe at a position remote from the base of the tower;

Figure 5 is a side view of the preferred embodiment of the invention with the concrete placement boom extended in a declined orientation so as to suspend a concrete supply pipe at a position remote from, and below, the base of the tower;

Figure 6 is a side view of the preferred embodiment of the invention showing two luffing positions that may be assumed by a distal member of the crane assembly;

Figure 7 is a cross sectional view of the turret and associated components, with the cross section taken through the centre of the turret;

Figures 8 to 13 are perspective partial views of the preferred embodiment of the invention, each taken from a different vantage point; and

Figures 14 to 18 are perspective cross sections views of the preferred embodiment of the invention, each taken from a different vantage point and with each cross section being through the centre of the turret.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, the construction apparatus 1 includes a tower 2, a turret 3 adapted for disposition upon the tower 2 via an adapter 49, a crane assembly 4 disposed on the turret 3 and a concrete placement boom 5 also disposed on the turret 3. It will be appreciated by those skilled in the art that the torque exerted on the tower 2 by the concrete placement boom 5 at least partially counterbalances the torque exerted on the tower 2 by the crane assembly 4. For at least some applications this counterbalancing effect negates the need for any counterweights, which helps minimise machinery fabrication costs and machine weight.

The crane assembly 4 defines a crane proximal end 6 and a crane distal end 7. The crane proximal end 6 is disposed on the turret 3 such that the crane distal end 7 projects from the tower 2 in a first direction. That is, as shown in figure 1 for example, the crane assembly 4 projects to the right hand side of the turret 3.

Similarly, the concrete placement boom 5 defines a boom proximal end 8 and a boom distal end 9. The boom proximal end 8 is disposed on the turret 3 such that the boom distal end 9 projects from the tower 2 in a second direction substantially opposite to said first direction. That is, as shown in figure 1 for example, the concrete placement boom 5 projects to the left hand side of the turret 3. Hence, in plan view, there is a 180° separation between the direction of the crane assembly 4 and the concrete placement boom 5. In other embodiments (not illustrated) the angular separation between the direction of the crane assembly 4 and the concrete placement boom 5 when viewed in plan is other than 180°. However, to benefit from at least some of the counter balancing effect, it is preferable for the crane assembly 4 and the concrete placement boom 5 to be separated by greater than 90° when viewed in plan.

The angular disposition of the concrete placement boom 5 relative to the turret 3 is selectively adjustable by means of actuating hydraulic ram 10 so as to pivot the concrete placement boom about horizontal pivot axis 11. Similarly, the angular disposition of the crane assembly 4 relative to the turret 3 is selectively adjustable by means of actuating hydraulic ram 12 so as to pivot the concrete placement boom about pivot axis 1 1 , That is, pivot axis 11 is common to the concrete placement boom 5 and the crane assembly 4.

The amount of torque exerted on the tower 2 by the concrete placement boom 5 is selectively adjustable by means of using hydraulic ram 10 to adjust the angular disposition of the concrete placement boom 5. This can be used to selectively counterbalance the torque being exerted on the tower 2 by the crane assembly 4, for example torque generated when using the crane assembly 4 to lift a load, as shown in figure 3. When the concrete placement boom S is rotated to a horizontal position, as shown for example in figure 3, it will exert a greater counterbalancing torque as compared to when it is rotated into a more vertical position. If further counter balancing torque is required from the concrete placement boom 5, it is possible to extend some or all of the hingedly interconnected members 13, 14, 15 and 16 of the concrete placement boom 5 so as to further displace the center of gravity of the concrete placement boom 5 from the pivot axis 11.

The turret 3 is rotatably disposed on the tower 2 by means of slew bearing 17 and the slew drive means 18. The axis of rotation of the turret 3 is vertical, extending through the centre of the tower 2. Rotation of the turret 3 effects rotation of the crane assembly 4 and of the concrete placement boom 5. A power pack 50 is also disposed on the turret 3 and also rotates therewith.

In the preferred embodiment the crane assembly 4 is a knuckled luffing crane assembly having a two hingedly interconnected crane members, including a proximal crane member 19 and a distal crane member 20. The end of the proximal crane member defines 19 the crane proximal end 6 and the opposite end of the crane distal member 20 defines the crane distal end 7. The proximal crane member 19 includes a tension member 21 attached to the crane proximal end 6 and to the other end 22 of the

proximal crane member 19. The tension member 21 is in the form of a steel rod or cable that extends substantially parallel to an elongate dimension of the proximal crane member 19, The connection 23 at the proximal end allows for selective pre- tensioning of the tension member 21 by screwing lock nut 24 along a threaded portion 25 of the tension member 21. It will be appreciate that higher amounts of pre- tensioning are appropriate for heavier lifting operations, and vice versa. The inclusion of the tension member 21 allows the proximal crane member 19 to be of a lighter construction for a given load bearing capacity.

A leading sheave 26 and a trailing sheave 27 are disposed at and adjacent the crane distal end 7 respectively for supporting a load carrying cable 28. The cable 28 is threaded intermediate the leading sheave 26 and the trailing sheave 27 so as to depend from either of the sheaves dependent upon an orientation of the distal crane member 20 relative to gravity. That is, when the distal crane member 20 is in an elevated position, as shown for example in the upper position of the distal crane member 20 in figure 6, the cable depends from the trailing sheave 27, Whereas, when the distal crane member is in a declined position, as shown for example in figure 2, the cable depends from the leading sheave 26. This arrangement allows the crane assembly to position loads extremely close to the base 29 of the tower 2, as shown in figure 2. In the configuration shown in figure 2, without the pair of sheaves 26 and 27, the cable would potentially depend from the proximal sheave 30 disposed on the proximal end off the distal crane member 20, which would be undesirable from a control and safety viewpoint. To allow the load to be positioned by the crane assembly 4 as close to the base 29 of the tower 2 as is illustrated in figure 2, the platform 32 includes a four open slots 46 through which the load carrying cable 28 may extend The slots 46 are illustrated for example in figure 9.

As noted earlier, the concrete placement boom 5 includes a plurality of hingedly interconnected boom members 13, 14, 15 and 16. The end of the proximal boom member 13 defines the boom proximal end 8. The proximal boom member 13 is approximately 66% longer than a longest length of the remaining boom members 14, 15 and 16. This additional length helps to position the majority of the weight of the concrete placement boom 5 at a position that is further away from the pivot axis 11.

This increases the maximum torque that can be exerted by the concrete placement boom 5 on the tower 2 as compared to the maximum torque that could otherwise be exerted if the proximal boom member 13 had the same length as the remaining boom members 14, 15 and 16. The additional length also provides the concrete placement boom 5 with some additional reach.

The concrete placement boom 5 has a range of movement sufficient to define a line of declination extending between the boom proximal end 8 and the boom distal end 9 that may be up to 25°from the horizontal. The concrete placement boom 5 is shown in such a configuration in figure 5 , This advantageously allows the operator to use the concrete placement boom 5 to supply concrete across a broad range of positions and elevations,

During assembly and disassembly another crane is typically used to separately lift each of the following modular components: the concrete placement boom 5; the crane assembly 4, with the exception of a proximal portion 31 of the proximal crane member 19; and the turret 3 and the proximal portion 31 of the proximal crane member 19. The ability to separately handle each of these modular components assists to minimise the weight of the heaviest lift required to assemble and disassemble the construction apparatus 1. For example, if the turret 3 were alternatively unbolted from the tower 2 with the crane assembly 4 and the concrete placement boom 5 still attached , the lift weight would be approximately 10 tonne for a typical preferred embodiment However, if disassembled as modular components as stated above, the heaviest lift is typically in the order of 4 tonnes. Hence, a lower capacity crane may be utilised to assemble and disassemble the construction apparatus 1, which advantageously assists to minimise costs.

The construction apparatus 1 also includes control means configured to permit separate operation of crane assembly 4 relative to concrete placement boom 5, and vice versa. In one operational mode, an operator stands on platform 32 and uses the control means to operate the construction apparatus 1. In another operational mode,

the control means is a remote control unit, allowing the operator to be positioned at an alternative vantage point whilst operating the construction apparatus 1. This is advantageous in certain situations, for example where visibility from the platform 32 is obscured,

As will be apparent from the foregoing discussion, the turret 3 has a crane assembly mounting means and a concrete placement boom mounting means. In the preferred embodiment, these two mounting means are together constituted by a pair of apertures 33 and 34 respectively disposed in a pair of lugs 35 and 36. Each of the lugs 35 and 36 are strengthened by webbing 45. The apertures 33 and 34 are adapted to house a corresponding pair of cylindrical outer sleeves 37 and 38 for mounting of a corresponding pair of apertures disposed at the crane proximal end 6 of the crane assembly 4. The outer sleeves 37 and 38 are adapted to receive a hollow cylindrical inner member 39 for mounting of corresponding apertures disposed at the boom proximal end 8 of the concrete placement boom 5. As shown for example in figure 7, the outer sleeves 37 and 38 are disposed at, or adjacent to, opposite ends of the inner member 39. The outer sleeves 37 and 38 are concentric with the inner member and more particularly, a radially inner surface of each of the sleeves 37 and 38 is in contact with a radially outer surface of the inner member 39, A pair of retaining members 42 and 43 is respectively fastened into abutment with one of the sleeves 37 or 38 and with one end of the inner member 39. Circular spacers, 47 and 48, are disposed intermediate the crane proximal end 6 and the boom proximal end 8 so as to isolate these two components from any friction arising from movement of one relative to the other. This assists the crane assembly 4 and the concrete placement boom 5 to rotate about pivot axis 11 independently of each other.

The rotatable mounting of the crane assembly 4 and the concrete placement boom 5 about a single common pivot axis 11 provides weight and space saving advantages.

During disassembly, the retaining members 42 and 43 are removed and the concrete placement boom 5 is supported by an external crane (not illustrated). The concrete placement boom 5 is detached from the turret 3 via removal of the inner member 39. During this first stage of disassembly, the outer sleeves 37 and 38 remain in place so

as to support the crane assembly 4. Once the removal of the concrete placement boom 5 has been completed, the crane assembly 4 is supported by the external crane, allowing the outer sleeves 37 and 38 to be removed and the crane assembly 4 to be detached from the turret 3. Alternatively, the sleeves 37 and 38 may be retained in place, and the proximal crane member 19 is split into two pieces by separating joint 44, Hence, the proximal portion 31 of the proximal crane member 19 remains attached to the turret 3 and the remainder of the crane assembly 5 is removed using the external crane. Finally, the turret, with proximal portion 31 still attached, is detached from the tower 2 and lowered to the ground by the external crane, allowing the tower 2 to be disassembled.

A concrete supply pipe 40 is threaded through the hollow inner member 39 as a convenient point of support for the concrete supply pipe 40, which extends along the concrete placement boom to terminate at outlet 41, (In some of the figures , for example figures 7 and 13 the concrete supply pipe 40 is not illustrated in its entirety, rather it is shown as terminating prematurely.)

The construction apparatus 1 enables an efficient construction method to be carried out This method commences with using the crane assembly 4 to position formwork so as to define at least one concrete receptacle. Once this step is completed, the turret 3 is rotated through approximately 180° to position the concrete placement boom 5 adjacent the work site. The concrete placement boom 5 is manoeuvred such that the outlet 41 of the concrete supply pipe 40 feeds into the concrete receptacle. Next concrete is pumped through the pipe 40, out of the outlet 41, and into the concrete receptacle defined by the formwork. It will be appreciated that this method is suited for construction of concrete structures such as buildings, car parks and the like. The preferred embodiment of the construction apparatus 1 is particularly suited for use with the formwork methods and apparatus that are disclosed in the applicant's co- pending International Patent Application No. PCT/AU2006/001252, filed on 30 August, 2006, the contents of which are hereby incorporated in their entirety by way of reference. However it will be appreciated that the range of potential uses of the . construction apparatus 1 is not limited to use with the formwork methods and apparatus disclosed in this co-pending application.

It will be appreciated that preferred embodiments of the present apparatus and methods may offer one or more of the following advantages:

* Space savings on construction work sites due to two functions being carried out by a single piece of apparatus;

• Ease of assembly and disassembly;

• Suspension of loads at positions that are very close to the base of the tower 2;

* Weight savings on the proximal member 19 of the crane assembly 4 due to the provision of a tension member 21; and • Quick alternation between jobs requiring a lifting capacity and jobs requiring concrete placement capacity.

Whilst the invention has been described with reference to specific examples, those skilled in the art will appreciate that it may be embodied in many other forms.