ELONGATE MEMBERS. METHODS OF THEIR CONSTRUCTION AND APPARATUS

THEREFOR

The present invention relates to elongate members or portions thereof and methods of their construction, for use in various structural applications such as but not limited to wind tower construction, tunnel or pipe construction.

BACKGROUND

Towers, tunnels, columns and other elongate structures are commonly used in construction. For instance, tall concrete towers may be constructed using multiple precast members that are cast at ground level and then lifted into position with a crane or lifting device to be assembled to form an elongate member as the primary part of the tower. There are two popular design approaches in constructing a round concrete tower, a) one uses a series of stacked pre-cast concrete rings or cylinders, and b) another uses a series of pre-cast semi-circular segments that are assembled and stacked.

Whilst commonly such towers may be cylindrical and hence of parallel walls, tapered, semi-conical, frustoconical or parabolic walled towers, when taken in a vertical section, may also be constructed. When of changing geometrical shape along its height, dedicated formwork may be required for multiple precast elements of the tower. This may hence involve a large number of formwork sections. This can incur high costs.

The process of creating pre-cast concrete rings or cylinders may comprise vertical standing formwork that may define an inner mould and an outer mould between which a concrete slurry can be poured, to then set to define a hollow concrete ring or cylinder. Hydrostatic pressure accumulated during pouring of the slurry can be very large depending on the height of the pour. Such pressure may be resolved by using formwork ties or by bands around the outer mould using hoop tension. The inner mould may also be appropriate re-enforced to help resist the pressure generated by the poured concrete.

Tall concrete rings of cylinders are desirable to generate as it means that less units need to be manufactured and handled to assemble a tower, hence providing a construction cost saving. However, a disadvantage of tall vertically cast concrete rings or cylinders is that the formwork used to create such, needs to be designed to cope with high hydrostatic loads and this may come at a high cost. Formwork ties may require high labour costs and may leave the wall with formwork tie holes.

The formwork costs for the pre-cast semi-circular segment approach may be lower than pre-cast rings or cylinders. However, the pre-cast semi-circular segments require grouted connections between each segment during tower assembly and this can be costly. A grouted connection may be established by a viscous settable liquid, typically cement-based, used to join two precast elements. Typically reinforcing is used within and spanning the joint to provide structural continuity between the precast elements. Having more parts required to assemble a tower adds to material and labour costs, including during construction.

As well as hydrostatic pressure design parameters needing to be taken into account, handling and transport of pre-cast components of a tower also create limitations on the size of the pre-cast ring, cylinder or segment to be created. Cranes may have a limited lifting capacity to handle the component of a tower being assembled and hence the total weight of a component may be limited by such factors. Whilst creating a tower from one pre-cast element may be feasible on paper, hydrostatic pressures, handling and transport limitations and construction costs may all play a role in the limits of what can or may desirably be done to create a tower or other elongate element such as pipes of tunnels of the like.

In this specification, where reference has been made to external sources of information, including patent specifications and other documents, this is generally for the purpose of providing a context for discussing the features of the present invention. Unless stated otherwise, reference to such sources of information is not to be construed, in any jurisdiction, as an admission that such sources of information are prior art or form part of the common general knowledge in the art.

For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be chronologically ordered in that sequence, unless there is no other logical manner of interpreting the sequence.

It is an object of the present invention to provide an elongate member and/or methods of its formation and/or apparatus therefor that overcomes or at least partially ameliorates some of the abovementioned disadvantages or which at least provides the public with a useful choice.

BRIEF DESCRIPTION OF THE INVENTION

In a first aspect the present invention may be said to be a method of forming an elongate member, the elongate member comprising an elongate central axis and formed horizontally of multiple abutting sections using a castable settable material, said sections notionally numbered sequentially along the length of the elongate member and at the interface of abutting sections, each section surface matched with an adjacent abutting section, where the method comprises the steps of a. forming a length of a circumferential segment of each odd-numbered sections in formwork defined by an outer shutter, inner shutter and stop ends to define outwardly facing end surfaces of said circumferential segments of the odd-numbered sections, by casting settable material into the formwork, b. removing the stop ends from and when the circumferential segments of (a) are set or partially set, c. forming a length of a circumferential segment of each even-numbered sections against the outwardly facing end surfaces of said odd-numbered sections and in formwork defined by an outer shutter and an inner shutter by casting settable material into the said formwork, d. when the circumferential segments of even-numbered sections of (c) are set or partially set, simultaneously rotating the formed circumferential segments of the odd-numbered and even-numbered sections about the central axis, and e. repeating steps a to d to form an endless series of abutting circumferential segments at each odd and even numbered sections.

Preferably abutting segments of each section are formed between different sections of the outer shutter and the same inner shutter.

Preferably the inner shutter is configured to move relative to the outer shutter and the outer shutter simultaneously rotates with the formed circumferential segments during step (d).

Preferably each circumferential segment when formed comprises and outwardly facing end face substantially orthogonal the elongate axis.

Preferably the outer shutter is configured to rotate about the elongate axis.

Preferably the outer shutter is supported on rollers configured to rotate the outer shutter about the elongate axis.

Preferably the inner shutter is located at the lowermost location within the outer shutter.

In a second aspect the present invention may be said to be a method of incrementally forming a section of or for an elongate member using a settable material, the section comprising an elongate central axis extending horizontally during forming of said section, where the method comprises the steps of: a. from a fluid settable material, forming a length (in the horizontal direction) of a circumferential segment of said section using formwork, b. when said length of said circumferential segment of (a) is set or partially set, rotating said circumferential segment of (a) about the central axis, and c. repeating steps a and b to form a plurality of lengths of circumferential segments of said section each abutting each other and until an endless series of adjacently abutting circumferential segments is established. Preferably the formwork comprising an outer shutter to form the circumference of the endless series of adjacently abutting circumferential segments.

Preferably the outer shutter is configured to rotate about the elongate axis.

Preferably the lengths of segments are formed between two seat members to each define outward facing surfaces at opposite ends of a section once formed.

Preferably each said seat member is cast from a settable material against another said seat member as a pair of seat members to define matching outward facing surfaces.

In a further aspect the present invention may be said to be a method of forming an elongate member, the elongate member comprising an elongate central axis and formed horizontally in multiple sections notionally numbered sequentially along the length of the elongate member, where the method comprises presenting in an abutting manner seat member pairs each at notional end faces of adjacent odd-numbered and even-numbered sections to be formed, and comprising the steps of a. from a fluid settable material, forming a length (in the horizontal direction) of a circumferential segment of the odd-numbered sections in formwork, b. from a fluid settable material, forming a length (in the horizontal direction) of a circumferential segment of the even-numbered sections in formwork, c. when the settable material of odd-numbered and even-numbered segments are set or partially set, simultaneously rotating both the odd- numbered and even-numbered partially formed sections about the central axis, and d. repeating steps a to c until the sections are formed continuous at their circumference.

In yet a further aspect the present invention may be said to be a method for assembling an elongate member from a series of sections each section comprising an elongate central axis where the method comprises; a. providing a plurality of seat member pairs each comprising two seat members comprising of matching faces to seat with each other in an abutting manner, b. presenting a seat member of one seat member pair at one notional end of a section to be formed and presenting a seat member of another seat member pair at the other notional end of said section to be formed, such that each seat members presents a said mating surface at opposite ends of said section to be formed, c. from a fluid settable material, forming a length of a circumferential segment of the section in formwork and between said seat member of one seat member pair at one notional end of a section to be formed and said seat member of another seat member pair at the other notional end of said section to be formed, d. when the length of the segment of the section is set or partially set, rotating the segment about the central axis, e. repeating steps b to c until the section is formed of an endless series of abutting segments continuous about its circumference, f. repeating steps a to e until a plurality of sections are formed, during, or after which, the sections are arranged, to define the elongate member, in sequence such that the matching faces of seat member pairs seat with each other in an abutting manner to define said elongate member.

In still a further aspect the present invention may be said to be a section of or for an elongate member constructed from a series of said sections positioned in an abutting manner in the elongate direction of the elongate member to for example define at least part of a tower or pipe or tunnel, said section comprising: between two opposed ends of the section at where respective outwardly facing end surfaces of said section are presented, a plurality of circumferential segments spanning between said opposed ends each individually and sequentially formed using a fluid settable material by a mould in an abutting manner defining the circumference of the section between the two opposed ends, wherein a first of said outwardly facing surface(s) is defined by one of (a) the circumferential segments and (b) a seat member against which the circumferential segments are formed, and wherein a second of said outwardly facing surface(s) is defined by one of (a) the circumferential segments and (b) another seat member against which the circumferential segments are formed.

Preferably the circumference between said opposed ends is prismatic or of a round sectional profile.

Preferably that is generally of a cylindrical or conical outer circumferential shape between opposed ends.

Preferably said circumferential segments together and at least at one of said opposed ends of the section define at least one surface that has been moulded by the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate member.

Preferably said circumferential segments together and at least at one of said opposed ends of the section define at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate member.

Preferably said circumferential segments at least at one of said opposed ends of the section have been cast during their forming against a said seat member that defines at least one surface that has been moulded by the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate member.

Preferably said circumferential segments have been cast against and between two seat members, one at each opposed end of the section, each seat member defining at least one surface matched to the surface(s) of an opposed end of like sections to respectively be at each opposed end of said first mentioned section adjacent and in abutment to said first mentioned section in the elongate member.

In yet a further aspect the present invention may be said to be an elongate member constructed from a stacked configuration (vertical or not) of a plurality of sections as herein described. Preferably at least one section has its circumferential segments together and at least at one of said opposed ends of the section define at least one surface that has been moulded by the surface(s) of an opposed end of a like section adjacent and in abutment to said first mentioned section in the elongate member.

Preferably at least one section has its circumferential segments together and at least at one of said opposed ends of the section define at least one surface that has been matched to the surface(s) of an opposed end of a like section adjacent and in abutment to said first mentioned section in the elongate member.

Preferably at least one section has its circumferential segments cast against and between two seat members, one at each opposed end of the section, each seat member defining at least one surface matched to the surface(s) of an opposed end of like sections to respectively at each opposed end of said first mentioned section adjacent and in abutment to said first mentioned section in the elongate member.

In yet a further aspect the present invention may be said to be an apparatus for casting at least one section of an elongate member from a settable material, the apparatus having a substantially horizontal elongate central axis and comprising: a. at least one formwork section to receive liquid settable material and configured to form a segment of the section from said settable material, the formwork section comprising: b. an outer shutter configured to form and define a radially- outward most outer surface of said segment, and c. a plurality of rollers supporting the formwork section allowing the outer shutter to be rotated about said elongate axis.

In a further aspect the present invention may be said to be a method of forming an elongate member or portion thereof, the elongate member comprising an elongate central axis and formed horizontally in multiple sections of a cast settable material notionally numbered sequentially along the length of the elongate member, each section face matched with an adjacent section when cast, where the method comprises the steps of a. providing the odd-numbered sections, b. forming a length of segment of the even-numbered sections between a formwork defined by an outer shutter, inner shutter and between end faces of said odd-numbered sections by casting a settable material into the formwork, c. when the even-numbered segments are set or partially set, simultaneously rotating both the odd-numbered sections and even-numbered partially formed sections about the central axis, and d. repeating steps b to c until the even-numbered sections are fully formed and continuous about their circumference..

Preferably the formwork comprising an outer shutter and inner shutter and stop ends to contain the fluid settable material during its setting, including at the ends of the length of each circumferential segment..

Preferably during forming of the segment, the inner shutter is located inside the outer shutter..

Preferably the method includes the step of the inner shutter being kept, or replaced, at its location as the outer shutter is, or has been, rotated..

Preferably the method includes the step of removing a top of the outer shutter once the section has been formed to allow the section to be removed from the outer shutter..

Preferably the stop ends are removed prior to or upon removal of the formed section from the formwork..

Preferable the seat members are made from a settable material..

Preferably the outward facing surface of a section is presented to abut against an outward facing surface of an adjacent said section.. Preferably the outward facing surface of first said section has a matching shape to the outward facing surface of an adjacent second said section to allow the first section and adjacent second section to abut together..

Preferably adjacent sections abut in a manner to register with each other..

Preferably adjacent sections abut in a manner to key with each other..

Preferably the outward facing surface of said first said section has been cast from a fluid settable material abutting the outward facing surface of an adjacent second said section to establish said matching shape between the outward facing surface of said first said section and the outward facing surface the second said section..

Preferably the seat members are pre-formed and are located with said formwork to provide a shuttering for said fluid settable material..

Preferably the elongate section comprises of a plurality of identical or like elongate sections stacked onto each other..

Preferably the elongate central axis is horizontal during the forming of the section..

Preferably the matching surfaces of a pair of seat members comprises castellations..

Preferably the seat members and lengths of segments are tied together using rebar..

Preferably the elongate member is of or to be used to define a tower structure or portion thereof..

Preferably the tower structure is of or to be used to define an on-shore tower structure or off-shore marine tower structure..

Preferably said tower structure comprises a supporting mast for a wind tower.. Preferably said elongate member or portion is of or to be used to define an underground tunnel structure or portion thereof..

Preferably the elongate member or portion thereof is of or to be used to define a marine pier structure or portion thereof..

Preferably said elongate member or portion thereof is of or to be used to define a supporting column for a building or the like..

Preferably the formwork of (a) is defined by an outer shutter, inner shutter and corresponding seat member of said seat member pairs adjacent to said odd-numbered sections..

Preferably the formwork of (b) is formwork defined by an outer shutter, inner shutter and corresponding seat members of said seat member pairs adjacent to said even- numbered..

Preferably the seat member pairs have matching surfaces to be or to be brought into contact is said abutting manner..

Preferably the matching surfaces are created by a casting from a settable material a seat member against another seat member of said seat member pair..

Preferably a said seat member of a seat member pair is formed as part an odd-numbered section and the other of said seat member of said seat member pair is formed as part of an even-numbered sections..

Preferably a said seat member of a seat member pair is formed as part an odd- numbered section and the other of said seat member of said seat member pair is formed as part of an even-numbered sections, said seat member pairs in the final assembly of the elongate member being seated together in an abutting manner..

Preferably the section is generally of constant cross section long its length..

Preferably the section is of the same cross sectional circumferential geometry along its length.. Preferably the section has a length-wise direction, to be parallel the elongate direction of the elongate member, terminated at each opposed end by outwardly facing surface or surfaces.

Preferably the or each section is elongate in the length-wise direction.

Preferably the or each section has been formed with its length-wise direction extending horizontally.

Preferably said section is of a notional diameter of at least 2m..

Preferably said section is of a notional diameter of at least 3m..

Preferably said section is of a notional diameter of at least 4m..

Preferably said section is of a notional diameter of at least 5m..

Preferably said section is of a notional diameter of at least 6m..

Preferably said section is of a notional diameter of at least 7m..

Preferably said section is of a notional diameter of less than 10m..

Preferably the or each section is an elongate section having opposed ends and said circumferential segments in abutment with each other and extending intermediate of the opposed ends..

Preferably the or each section is an elongate section having opposed ends and said circumferential segments in abutment with each other and extending to the opposed ends..

Preferably the or each section is of a prismatic form at least at its circumference..

Preferably the or each section is of a cylindrical form at least at its circumference..

Preferably the or each section is hollow.. Preferably the or each section has a passage passing along it and preferably through it in the elongate direction.

Preferably the or each section has a passage passing along it and preferably through it between the opposed ends and in the elongate direction.

Preferably the passage is of the same but scaled down geometric shape in cross section as the circumference of the section at a given cross section..

Preferably the passage is of a different geometric shape in cross section as the circumference of the section at a given cross section..

Preferably the circumferential segments of the section define the circumference of the section.

Preferably the circumferential segments of the section define the passage of the section.

Preferably for the or each section, the circumferential segments are arranged in abutting series with one another about a notional axis that extends in the length-wise direction.

Preferably the or each section comprises said circumferential segments together and at least at one of said opposed ends of the section defining at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate structure, by said circumferential segments having been moulded by the surface(s) of an opposed end of a like section.

Preferably the or each section comprises said circumferential segments together and at least at one of said opposed ends of the section defining at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate structure, by said circumferential segments having been mould casted against the surface(s) of an opposed end of a like section. Preferably the or each section comprises said circumferential segments together and at least at one of said opposed ends of the section defining at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate structure, by said circumferential segments, when being formed, having been moulded against the surface(s) of an opposed end of a like section.

Preferably the or each section comprises said circumferential segments together and at both of said opposed ends of the section defining at least one surface that has been moulded by the surface(s) of an opposed end of like sections to respectively be at each opposed end of said first mentioned section adjacent and in abutment to said first mentioned section in the elongate member.

Preferably the or each section comprises said circumferential segments that at least at one of said opposed ends of the section have been cast against a seat member that has at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate member.

Preferably the or each section comprises said circumferential segments that at least at one of said opposed ends of the section have been cast against a seat member that has at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate structure, by said seat member having been moulded by the surface(s) of an opposed end of a like section.

Preferably the or each section comprises said circumferential segments that at least at one of said opposed ends of the section have been formed by a seat member that has at least one surface that has been matched to the surface(s) of an opposed end of a like section to be adjacent and in abutment to said first mentioned section in the elongate structure, by said seat member having been moulded by the surface(s) of an opposed end of a like section. Preferably the or each section comprises said circumferential segments that at both of said opposed ends of the section have been cast against a seat member at each opposed end, each seat member defining at least one surface that has been moulded by the surface(s) of an opposed end of like sections to respectively be at each opposed end of said first mentioned section adjacent and in abutment to said first mentioned section in the elongate member.

Preferably the or each section comprises said circumferential segments that at both of said opposed ends of the section have been formed by a seat member at each opposed end, each seat member defining at least one surface that has been moulded by the surface(s) of an opposed end of like sections to respectively be at each opposed end of said first mentioned section adjacent and in abutment to said first mentioned section in the elongate member

Preferably the or each section comprises said circumferential segments that have been cast against and between two seat members, one at each opposed end of the section, each seat member defining at least one surface that has been moulded by the surface(s) of an opposed end of like sections to respectively be at each opposed end of said first mentioned section adjacent and in abutment to said first mentioned section in the elongate member.

Preferably said seat member has at least one surface to be in abutment with a surface(s) of a seat member to be adjacent the first mentioned seat member in the elongate structure, by having been moulded by the surface(s) of the seat member to be adjacent in the elongate structure.

Preferably said seat member has at least one surface moulded by a surface(s) of a seat member to be adjacent the first mentioned seat member in the elongate structure.

Preferably a pair of said seat members are formed together from a fluid settable material in a manner so as to create at least one surface of a first seat member of said pair that is a negative shape of the second seat member of said pair. Preferably a pair of said seat members are cast together from a fluid settable material in a manner so as to create at least one surface of a first seat member of said pair that is a negative shape of the at least one surface of the second seat member of said pair.

Preferably a pair of said seat members are cast using poured concrete in a manner so as to create at least one surface of a first seat member of said pair that is a negative shape of the at least one surface of the second seat member of said pair.

Preferably the seat member is formed against a like seat member to create a surface or surfaces of said seat member that is of a negative shape a positive shape of the surface or surfaces of said like seat member.

Preferably the seat member and like seat member are, in said elongate member, positioned adjacent and in abutment with each other with the negative shape and the positive shape mating together.

Preferably the seat member is assembled from a plurality of seat member segments arranged in series abutting each other.

Preferably the thickness of one or both of the seat members of a seat member pair may vary to define a wedge shaped or tapered seat member..

Preferably the thickness of one or both of the seat members of a seat member pair may vary to define a wedge shaped or tapered seat member to allow a non linear elongate member of a plurality of sections to be created..

Preferably the use of a wedge or tapered seat member allows the arrangement of adjacent abutting sections in a manner to have their the length-wise directions non parallel each other..

Preferably said sections abut (or are to) each other in a vertically stacked manner..

Preferably said sections abut (or are to) each other in a horizontally stacked manner.. Preferably said sections abut (or are to) each other in an inclined to the horizontal stacked manner..

Preferably the elongate member is a tower..

Preferably the elongate member is a tube..

Preferably the elongate member is a tunnel..

Preferably the elongate member is a pipe..

Preferably the formwork also comprises an inner shutter configured to form and define a radially-inward inner surface of said segment..

Preferably the inner shutter and outer shutter cooperate to help form a segment and are configured to move relative each other to release the segment from the inner and outer shutter..

Preferably a seat member is arranged at one end of said formwork section in between said shutters and another seat member is arranged at another end of said formwork section in between said shutters..

Preferably said seat member at one end of said formwork section forms part of the section once cast and has an cast surface that is a negative of and formed by a surface of corresponding seat member with which is it to abut, provided by a like section..

Preferably a plurality of said formwork sections are arranged coaxially and adjacent one another so configured to form a plurality of sections from a settable material..

Preferably the method includes the step of the inner shutter being kept, or replaced, at its location as the outer shutter is, or has been, rotated..

Preferably the method includes the step of moving a section and its respective formwork laterally in the direction along the elongate axis..

Preferably the method includes the step of removing a top half of the outer shutter.. Preferably method includes the step of removing a formed section from the formwork..

Preferably the outer shutters form a cylinder or frustoconical cylinder configured to define the outside surface of a section..

Preferably formwork sections are adjacent to each other along the elongate axis.. Preferably the elongate axis is substantially horizontal when the apparatus is in use..

Preferably one or more of the multiple formwork sections are configured to be moved laterally along the elongate axis..

Preferably the outer shutter comprises a removable or movable top half allows a cast section to be removed..

Preferably one or more of the plurality of rollers are driven, and/or one or more of the plurality of rollers are passive..

Preferably method comprises the step of applying a release agent to the arc end faces that will face an adjacent length of segment..

Preferably the outer shutter is formed in at least two sections configured to allow a section to be removed from the formwork..

In a further aspect, the present invention consists in a method for forming a hollow wind turbine tower or portion thereof from a settable material, the tower during casting comprising a substantially horizontal elongate central axis, the tower cast in multiple tubes notionally numbered sequentially along the length of the tower, each tube face matched with an adjacent tube when cast, where the method comprises the steps of a. forming a length of segment of the odd-numbered tubes between a formwork defined by an outer shutter, inner shutter and stop ends via locating settable material into the formwork, b. removing the stop ends when the segments are set or partially set, c. forming a length of segment of an even-numbered tube between end faces of said odd-numbered tubes and a formwork defined by an outer shutter and an inner shutter via locating settable material into the said formwork, d. when even-numbered segments are set or partially set, simultaneously rotating both the odd-numbered and even-numbered partially formed tubes, and e. repeating steps a to d until the tubes are fully formed and continuous about their periphery.

In another aspect the present invention may be a method of incrementally forming a section of a tower. The method may involve horizontally forming a length a circumferential segment of the section from a fluid settable material, using formwork. When the length is set or partially set the formwork is rotated about the central axis to present a non-occupied region of the form work at where the next circumferential segment can be formed from a fluid settable material. This it then repeated until a plurality of lengths of circumferential segments are created, each abutting each other to define endless series of adjacently abutting circumferential segments.

In another aspect, the present invention consists method for casting a hollow wind turbine tower or portion thereof from a settable material, the tower when formed comprising a substantially horizontal elongate central axis, the tower formed of multiple tubes notionally numbered sequentially along the length of the tower, each tube face matched with an adjacent tube when cast, where the method comprises the steps of a. providing the odd-numbered tubes, b. forming a length of segment of the even-numbered tubes between a formwork defined by an outer shutter, inner shutter and between end faces of said odd-numbered tubes via locating settable material into the formwork, c. when the even-numbered segments are set or partially set, simultaneously rotating both the odd-numbered tubes and even-numbered partially formed tubes about the central axis, and d. repeating steps b to c until the even-numbered tubes are fully formed and continuous about their circumference

In one embodiment, the odd-numbered tube is formed in segments like the even-numbered tubes. Wherein the below embodiments relate to the above two inventions.

In one embodiment, the tubes are removable from the formwork..

In one embodiment, the formwork is supported on rollers..

In one embodiment, the forming of a segment occurs at the lowest point in the outer shutter..

In one embodiment, the radially adjacent segments are formed between different sections of the outer shutter and the same inner shutter..

In one embodiment, the inner shutter is configured to move relative to the outer shutter..

In one embodiment, each segment when formed comprises end faces substantially orthogonal the elongate axis..

Alternatively, each segment when formed comprises end faces substantially parallel the end faces of an adjacent..

In one embodiment, the method comprises the step of applying a release agent to the arc end faces that will face an adjacent length of segment..

In one embodiment, an odd-numbered tube is formed between an even- numbered tube face ends, or segment face ends, that face each other..

In one embodiment, the faces ends of the odd-numbered tube matches i.e. is a mirror image of, the respective adjacent end of the adjacent even-numbered tube..

In one embodiment, the settable material comprises a releasing agent..

In one embodiment, the outer shutter is formed in at least two sections configured to allow a tube to be removed from the formwork..

In one embodiment, adjacent tubes are configured to be separated from each other.. In one embodiment, the outer shutters have an arc width between 1/16 of the circumference and ½ of the circumference of the tube, preferable the width of the arc of the outer shutter is ¼ the circumference of the tube..

In one embodiment, the length of the segment has a length along the elongate axis the same length as the respective tube..

In one embodiment, the inner shutters have an arc width between 1/16 of the circumference and ½ of the circumference of the tube, preferable arc width section is ¼ the circumference of the tube..

In one embodiment, the width of the segment is any one between 1/16 of the circumference and ½ of the circumference of the tube, preferable the width of the segment is ¼ the circumference of the tube..

In one embodiment, the outer shutter is configured to rotate about the elongate axis..

In one embodiment, the outer shutter is supported on rollers configured to rotate the outer shutter about the elongate axis..

In one embodiment, the inner shutter is located at the lowermost location within the outer shutter. .

In one embodiment, the method includes the step of the inner shutter being kept, or replaced, at its location as the outer shutter is, or has been, rotated..

In one embodiment, the inner shutter is supported on rollers configured to allow the inner shutter to remain in its location as the outer shutter is rotated..

In one embodiment, the inner shutter is biased by gravity to remain in the same location as the outer shutter is located..

In one embodiment, the outer shutter is cylinder-shaped.. In one embodiment, the method includes the step of adding reinforcing into the formwork before forming..

In one embodiment, the tube is formed with rebar within it..

In one embodiment, the formwork for a tube is separable from the formwork for an adjacent tube..

In one embodiment, the formwork of one tube is not connected to the adjacent tube.

In one embodiment, the formwork of one tube overlaps the formed arc..

In one embodiment, the method includes the step of moving a tube and its respective formwork laterally in the direction along the elongate axis..

In one embodiment, the method includes the step of removing a top half of the outer shutter..

In one embodiment, the method includes the step of removing a formed tube from the formwork..

In one embodiment, the tower is formed horizontally..

In one embodiment, the tubes are frustoconical..

In one embodiment, each tube has a similar mass..

In one embodiment, the rollers are driven simultaneously to each other..

In one embodiment, the rollers are driven at different speeds to account for the differing diameter of tube..

In one embodiment, the settable material is concrete.. In a further aspect, the present invention consists in a mould for casting a tubular wind turbine tower from a settable material, the tower having an elongate axis and formed from multiple tubes, the apparatus comprising a. multiple formwork sections configured to each form a segment of the said tube from a settable material, each formwork section comprising i. outer shutters configured to engage together to form a periphery to define an outer surface of said segment, and ii. an inner shutter configured to form a portion of an inside surface of said segment, and the inner shutter configured to move relative the outer shutter, and b. a plurality of rollers supporting the formwork allowing the outer shutter to be rotated about its elongate axis.

In one embodiment, the outer shutters form a cylinder or frustoconical cylinder configured to define the outside surface of a tube..

In one embodiment, the formwork sections are adjacent to each other along the elongate axis..

In one embodiment, the elongate axis is substantially horizontal when the mould is in use..

In one embodiment, the multiple formwork sections are rotatable..

In one embodiment, one or more of the multiple formwork sections are configured to be moved laterally along the elongate axis..

In one embodiment, the rollers are configured to be moved laterally along the elongate axis to move the one or more of the multiple formwork sections laterally along the elongate axis..

In one embodiment, the outer shutter comprises a removable or movable top half allows a cast tube to be removed.. In one embodiment, the outer shutter comprises guides to engage with the rollers..

In one embodiment, one or more of the plurality of rollers are driven, and/or one or more of the plurality of rollers are passive..

In one embodiment, the formwork section comprises end stops to define the end faces of the segments..

In one embodiment, the inner shutter comprises an inlet to receive settable material..

In one embodiment, the formwork section is configured to receive settable material between the inner shutter and outer shutter at the segment horizontal sides..

In one embodiment, the settable material is concrete..

In one embodiment, the formwork section does not comprise multiple inner shutters..

In one embodiment, the formwork section only has one inner shutter..

In one embodiment, there is no formwork that defines an inner surface of a tube that is above half the height of the mould..

In another aspect, the present invention consists in a method for casting a hollow wind turbine tower or portion thereof from a settable material, the tower during casting comprising a substantially horizontal elongate axis and formed from multiple tubes, where the method comprises the steps of a. forming a length of tube with settable material via the following formation steps: i. forming a segment via pouring settable material into a formwork defining an arc length of said tube, ii. when said segment is cured, simultaneously rotating about the elongate axis an outside shutter of the formwork that defines an outside surface of the segment, and the segment, iii. forming a subsequent segment radially adjacent to the previously formed segment, and iv. repeating steps ii-iii until the tube has a continuously formed circumference, wherein one end face of the tube substantially orthogonal to the elongate axis defines a tower end, b. forming a subsequent length of tube via the formation steps, the tube spaced in the elongate direction away from and opposing the tower end, c. forming an intermediate tube via the formation steps intermediate the spaced-apart tubes, the three tubes being continuous with each other and their end defining a new tower end..

In one embodiment, the method comprises the step of repeating steps b. and c. until a desired length tower is formed..

In one embodiment, the tubes are formed by formwork comprising at least i. the outer shutter configured to define an outside surface of said tubes, and ii. an inner shutter configured to form a portion of an inside surface of said tubes

In one embodiment, the inner shutter defines an arc of the inside surface of a tube during each forming,

In one embodiment, the outer shutter defines at least an arc of the outside surface of a tube during each forming..

In one embodiment, the inner shutter is configured to move relative to the outer shutter.. In one embodiment, the radially adjacent segments are formed between different sections of the outer shutter and the same inner shutter..

In one embodiment, each tube, when formed comprises end faces substantially orthogonal the elongate axis..

In one embodiment, the intermediate tube is formed between the first and second tube ends that face each other..

In one embodiment, the ends of the intermediate tube match the respective adjacent end of the first and second tube..

In one embodiment, the ends of the first tube and second tube comprise a releasing agent..

In one embodiment, the settable material comprises a releasing agent..

In one embodiment, adjacent tubes are configured to be released from each other..

In one embodiment, the outer shutter is formed in at least two sections configured to allow a tube to be removed from the outer shutter..

In one embodiment, the formwork for a tube is separable from the formwork for an adjacent tube..

In one embodiment, the outer shutter is supported on rollers configured to rotate the outer shutter about the elongate axis..

In one embodiment, the inner shutter is located at the lowermost location of within the outer shutter.

In one embodiment, the inner shutter is supported on rollers configured to allow the inner shutter to remain in its location as the outer shutter is rotated..

In one embodiment, the inner shutter is kept, or replaced, at its location as the outer shutter is, or has been, rotated.. In one embodiment, the inner shutter is biased by gravity to remain in the same location as the outer shutter is located..

In one embodiment, the outer shutter is cylinder-shaped..

In one embodiment, the tube is formed with rebar within it..

In one embodiment, the settable material is concrete..

In a further aspect, the present invention consists of a method of casting a wind tower horizontally in multiple tubes one segment of a tube at a time, the method comprising the steps of, pouring settable material into spaced apart formwork to form a lowermost segment of said tube and once the settable material is cured applying a release agent to the end faces of the segment; pouring settable material into intermediate formwork intermediate the spaced apart formwork; rotating the formed segment and formwork (both spaced apart formwork and intermediate formwork) about an elongate axis of the tower; repeating the process until the tubes are complete..

In one embodiment, the method comprises the step of removing a top half of the formwork to allow tubes to be removed from the formwork..

In one embodiment, the formwork is comprised of an outer shutter and inner shutter; the inner shutter configured to define an inner surface of each segment, the inner shutter configured to move relative the rotatable outer shutter so as to be located in a position after each rotation to form the inner surface of the next segment to be poured.

In a further aspect, the present invention consists of a mould for casting a hollow wind turbine tower or portion thereof from concrete, the mould comprising formwork sections along the length of the mould, each formwork section comprising an inner shutter to define an inner surface of a segment of the tower, and an outer shutter to define the outer surface of the tower, the outer shutter supported by rollers configured to rotate the outer shutter about an elongate axis of the mould, the inner shutter configured to move relative the outer shutter so as to remain in place or be relocated, as the outer shutter is rotated.. In one embodiment, the formwork sections are laterally separable from each other in a direction along said elongate axis..

In one embodiment, the formwork sections comprise a removable section to allow a cast portion of the tower to be removed..

In one embodiment, the formwork sections comprise end face stop ends between adjacent formwork sections..

In one embodiment, the stop ends are removable..

In one embodiment, the elongate axis is horizontal..

In a further aspect, the present invention consists in a method of cast forming from a settable material sequentially stackable tubes to form a hollow vertical wind turbine tower that are identically sequenced in a horizontal manner when so cast formed, where the method comprises: intermediate of prior cast notionally odd-numbered tubes of said stackable tubes that are spaced apart and extending along a horizontally axis, segmentally casting the notionally even-numbered tubes, end matched by and to adjacent said odd-numbered tubes to define, in a horizontally extending condition the assembled wind turbine tower, the tubes able to be disassembled from this condition for subsequent in-situ stacking to define the hollow vertical wind tower..

In one embodiment, the notionally odd-numbered tubes are segmentally cast in segments and in said spaced apart manner extending along the horizontal axis..

In one embodiment, the segments have an arc-shaped cross-section..

In one embodiment, the odd-numbered tubes and are formed by forming a length of a segment of notionally odd-numbered tubes between a formwork defined by an outer shutter, inner shutter and stop ends via locating settable material into the formwork.. In one embodiment, the odd-numbered tubes are formed by repeated forming segments until the tube is formed..

In one embodiment, the segments of the even-numbered tubes are formed subsequent a segment of an adjacent odd-numbered tube.

Alternatively, the odd-numbered tubes are fully formed before forming the even- numbered tubes.

In one embodiment, the tubes are formed by a. pouring the settable material into the odd numbered segment formwork, b. removing the stop ends of the odd-numbered tubes when a segment is set or partially set, c. forming a length of segment of an even-numbered tube between end faces of said odd-numbered tubes and a formwork defined by an outer shutter and an inner shutter via locating settable material into the said formwork, d. when even-numbered segments are set or partially set, simultaneously rotating both the odd-numbered and even-numbered partially formed tubes, and e. repeating steps a to d until the tubes are fully formed and continuous about their periphery..

In one embodiment, the formwork is defined by an outer shutter, inner shutter and stop ends via locating settable material into the formwork..

In one embodiment, the tubes are removable from the formwork..

In one embodiment, the formwork is supported on rollers..

In one embodiment, the forming of a segment occurs at the lowest point in the outer shutter..

In one embodiment, the radially adjacent segments are formed between different sections of the outer shutter and the same inner shutter.. In one embodiment, the inner shutter is configured to move relative to the outer shutter..

In one embodiment, each segment when formed comprises end faces substantially orthogonal the elongate axis..

In one embodiment, the method comprises the step of applying a release agent to the arc end faces that will face an adjacent length of segment..

In one embodiment, an odd-numbered tube is formed between an even- numbered tube face ends, or segment face ends, that face each other..

In one embodiment, the outer shutter is configured to rotate about the elongate axis..

In one embodiment, the outer shutter is supported on rollers configured to rotate the outer shutter about the elongate axis..

In one embodiment, the inner shutter is located at the lowermost location within the outer shutter..

In one embodiment, the method includes the step of the inner shutter being kept, or replaced, at its location as the outer shutter is, or has been, rotated..

In one embodiment, the inner shutter is supported on rollers configured to allow the inner shutter to remain in its location as the outer shutter is rotated..

In one embodiment, the inner shutter is biased by gravity to remain in the same location as the outer shutter is located..

In one embodiment, the outer shutter is cylinder-shaped..

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun.

The term "comprising" as used in this specification [and claims] means "consisting at least in part of”. When interpreting statements in this specification [and claims] which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.

BRIEF DESCRIPTION OF THE FIGURES

The invention will now be described by way of example only, with predominant reference to its application in the construction of towers, and with reference to the drawings in which:

Figures 1A-1D: shows a front schematic view of a section of for example a tower, being formed in segments in a formwork. Figure 2: shows a side schematic view of a mould that may be used to create a long section of a tower or the full length of a tower,

Figure 3: shows an end side perspective view of an example of an outer shutter of the formwork that may be used to create a tower or tower section,

Figure 4: shows subsequent views of (a) rebar being inserted into a lower half of an outer shutter on the left, and subsequently (b) the top half of the outer shutter being engaged with the lower half of the outer shutter on the right. Figure 5: shows a side schematic view of a mould with a formwork section being laterally spaced from the adjacent formwork section.

Figure 6A: shows a cross-sectional side schematic view of first pours 1, 2 and 3 of segments in notionally odd-numbered spaced apart sections of formwork defined by appropriate shuttering.

Figure 6B: shows pours 4, 5 and 6 of segments, poured subsequent to the pours

1, 2 and 3, in the notionally even-numbered spaced apart sections of formwork that are intermediate of the even numbers sections of formwork and that are defined by appropriate shuttering and by the ends of the segments of pours 1, 2 and 3.

Figure 7: shows an end schematic view of a section of a tower within outer shuttering of formwork.

Figure 8: shows an end schematic view with a section of tower removed from a lower half of outer shuttering of formwork. Figure 9: shows an end schematic view of an inner shuttering of formwork and corresponding segment of a section of a tower, for clarity shown absent of outer shuttering.

Figure 1(k shows a front top perspective view of a portion of a tapered tower formed from multiple sections. Figures 11A-D: show, in sequence, end schematic views of subsequent poured segments for forming a tapered section (as seen in figure 11D) for a tapered tower such as seen in figure 10.

Figure 12: shows a side schematic view of a mould and a concrete pour line, Figure 13A: shows a side schematic cross section view of formwork for forming a seat member pair.

Figure 13B: shows a top schematic view of formwork for forming segments of a seat member pair.

Figure 14A: shows a side schematic view of two tower sections being formed that have seat members at their ends. Figure 14B: shows a side schematic view of three completed tower sections assembled together by respective end-matched seat member pairs. Figure 15 A: shows a side schematic view of a seat member pair with complimentary shaped castellations.

Figure 1 SB: shows a side schematic cross section view of a wedge shaped seat member pair. Figure 15C: shows a side schematic view of two sections, of an elongate member such as part of a tunnel or pipe, coupled together by the wedge shaped seat member pair of figure 15B.

Figure 16A: shows a perspective schematic view of a segment of a tower section, formed between two pre-cast seat member pairs and inner and outer shuttering.

Figure 16B: shows a perspective schematic view of a segment of a tower section, formed between pre-cast circumferential segments of two seat members.

Figure 17A-B: shows schematic plan views of the circumferential segments of a section that may be formed.

Figure 18: shows a perspective schematic view of a wind turbine tower constructed by the methods and moulds described herein.

DETAILED DESCRIPTION

The present invention relates to elongate members, methods and associated apparatus for forming elongate members, using a settable material such as concrete.

An elongate member according to an example of the present invention may be formed solid or hollow in cross section, either of a straight or at least partially non straight longitudinal configuration. When hollow it may define a passage in the elongate direction therethrough. In a preferred form the elongate member is cylindrical and preferably tubular and hence generally circular in peripheral cross-sectional shape. However, it may be of other shape such as prismatic (eg being polygonal in cross section such as triangular, square, hexagonal or octagonal, for example) and have a corresponding or otherwise non-corresponding polygonal, triangular, hexagonal or octagonal internal peripheral cross sectional shape.

Preferably the elongate member is hollow of a substantially cylindrical or tapered circular peripheral shape. It is preferably made by using a settable material in a cast manner. The settable material may hence be a castable settable material such as pourable concrete. Before setting the settable material is fluid to allow it to be poured.

In a preferred form the elongate member may be defined by multiple sections. The have a length-wise direction to be parallel the elongate axis when assembled as part of the elongate member. At the end of the length of a section are its opposed ends that may be defined by at least one outwardly facing surface as will herein after be descried.

Since the sections are arranged to define the elongate member they may also each be cylindrical and preferably tubular and hence generally circular in peripheral cross- sectional shape as the case may be. However, each section may be of other shape such as prismatic (eg being polygonal in cross section such as triangular, square, hexagonal or octagonal, for example) and have a corresponding or otherwise non-corresponding polygonal, triangular, hexagonal or octagonal internal peripheral cross sectional shape. Such sections are also preferably hollow and have a passage passing there through and through its opposed ends. The sections of an elongate member may not all be identical. For example if the elongate member is to define a tower for a wind power generator, the tower may be tapered and hence sections higher up may be of a smaller diameter than those at or near the base of the tower.

The sections may be formed concurrently or sequentially and may be formed adjacently or separately as will herein be described. The elongate member may be formed as a unitary item in a mould by a plurality of the sections or may be assembled from separately formed sections or a combination thereof.

Examples of structures which may be constructed using an elongate member that may be formed from the said methods and apparatuses described herein, include but are not limited to tower structures, such as on-shore or off-shore marine tower structures, including those that may be used as wind power generator towers, tower structures for buildings or high-rises or the like, pipes, lengths of underground tunnel structures (i.e., road vehicle transport tunnels), partially or fully submerged marine support structures such as pier columns, or supporting columns and structures in general for the construction of buildings or high-rises of various kinds. As a tunnel or a pipe the passage defined through said elongate member provides a transport conduit and location for utilities.

As a tower the passage defined through said elongate member provides an access passage and location for utilities.

Therefore, whilst the examples provided herein refer largely to elongate members and their formation for the use in towers such as wind power generator towers that may be used for onshore or off shore installs, and while some benefits described herein arise in particular when said methods are employed in said construction of wind towers, those skilled in the art will appreciate that the disclosures may be applied equally to the construction of a wide variety of structures, and that many of the benefits or advantages described herein in relation to wind tower construction may equally apply a wide variety of structures as well.

Thus, when the term tower is used throughout this specification, it refers to an elongate portion of a tower, where any functions and features thereof, as well as any methods or means of formation, construction and assembly, being applicable to elongate members in any other applications, such as those herein described. The terms tower and elongate member may hence be used interchangeably throughout this section of the specification.

The general process of one embodiment of the method of forming a section 20, as also seen in figure 10, of an elongate member 10 (such as a tower) will be described with reference to Figures 1A-1D. The tower 10 may be formed of multiple sections 20 configured to have a substantially elongate central axis 11. The sections 20 may be formed together to define the elongate member of the tower 10. The sections have a general length wise direction that is parallel to the central axis 11. They are preferably formed using a settable material and with the elongate axis extending horizontally. Where the elongate member is a tower, it may be moved from its horizontal condition in which it is formed, to an erect condition by being tilted upwardly. It may be transported over land or sea in its horizontal condition prior to being tilted upwardly and in its final location of use.

Each section 20 may generally comprise a body 20A (shown in Figure 16A) having two opposed and spaced apart ends each to abut with another like section 20 (when said sections 20 are brought together, or cast adjacent one another as will be described, to become said elongate member 10). Intermediate of these ends is a cast portion 20B (shown in Figure 16A) formed by a plurality of lengths of circumferential segments 36A, 36B, 36C ... etc. (i.e., as shown in Figures 1A-1D where a cast portion 20B is so formed by four circumferential segments 36A-36D).

The cast portion 20B is formed generally by settable material using shuttering, as described in the method below, which may comprise the steps of: a. forming a horizonal length in the lengthwise direction, of a circumferential segment 36A of said cast portion 20B between formwork 40 that may be defined by an outer shutter 44, inner shutter 41 and stop ends (not shown in Figures 1A-1D but placed at lateral ends of the formwork 40 to define the opposed and spaced apart ends of the cast portion 20B) by casting (such as by pouring) a settable material appropriately into the formwork 40 between the shutters and stop ends, b. when said length of the first segment 36A is set or partially set (in Figure 1A the segment 36B has just been cast, whereas in Figure 1B, said segment 36A is the prior cast segment in Figure 1A that has cured or set or at least partially set), rotating said partially formed cast portion 20B about the central axis 11, and c. repeating steps a and b so as to cast from a settable material, a plurality of lengths of circumferential segments 36A-36D of said cast portion 20B until the cast portion 20B is fully formed and continuous about its circumference (e.g. it is fully formed when a plurality of abutting and adjacent circumferential segments are provided in an endless series. It is endless in the manner that a circle is endless and likewise a square or other polygonal has an endless perimeter).

Thus, shown schematically in sequence in Figures 1A-1D, is the roughly quarter circumferential segments 36A-36D being successively formed adjacent one another. This segmental formation of a section 20 of an elongate member is also exemplified in Figures 11A-11 D, described in further detail below, which show the currently-being-cast segment

36A-36D forming into cured segments and rotated so as to permit casting of the next adjacent segment. Generally, to form an entire cast portion 20B of a section 20, the formwork 40 is able to be rotated such that new segments can be defined at the lower bottom area of the formwork, preferably adjacent, the previously formed segment 36. The formwork, or formwork section 40 for example need to be rotated in increments that add up to 360" to allow the section 20 to be fully circumferentially formed.

By forming a section 20 of the tower 10 segmentally and horizontally the 'height' H of a pour of concrete for one circumferential segment being formed (when oriented horizontally in the formwork 40 as shown in Figure 12) can be kept sufficiently low. For large diameter sections this can be advantages as it can help keep hydrostatic pressures in check and thereby ensure that the formwork used to create a section can be designed economically and practically to handle the pressure of the poured concrete. Should a section be poured in one pour and have a hydrostatic head equal to the diameter of the section, the formwork required to adequately contain the hydrostatic forces, may be impossible to provide in a practical sense.

Figure 12 also shows the maximum fill upper-level 63 of for poured concrete for formed segments 36 being the same as said height H. Note that the horizontal elongate axis 11 or level of the mould 14 is generally in line with the top of the first section on the left. Casting a section in segments results in a maximum hydrostatic head H of settable material being substantially less than D and this means a significant reduction in hydrostatic pressure during casting, and thus less cost in terms of handling and manufacturing of the formwork 40.

Notional diameter may refer to the literal external edge-to-edge diameter when a circular or elliptical cross-section shaped section 20 is being formed, or may otherwise refer to the diameter of a notional circle drawn tangent to the most spaced apart edges of a non-circular cross-section shaped section 20 (such as triangular, polygonal section as described above).

The above method of forming a single section 20 in a single formwork 40 is also generally applicable when multiple sections 20 are cast adjacent one another within a plurality of adjacent formworks 40 together defining a larger mould 14 i.e., such as when an elongate member 10 or potion thereof requiring multiple sections 20 is desired for construction. Said plurality of adjacent formworks 40 of a larger mould 14 may be configured to cooperate with one another (i.e., by coupling together adjacent shuttering thereof) so as to be rotated as one unit, as shown and described in relation to Figure 2-

12.

Such a mould 14 according to one embodiment of the present invention hereinafter relates to a more specific formwork system for a plurality of end-matched adjacent pre-cast sections for a wind turbine tower elongate member 10, and may overcome the drawbacks of the current tower casting methods.

The below description of said embodiment in relation to wind tower elongate member construction/assembly may apply equally to other non-wind-tower elongate member embodiments of the present invention, as has been described above.

Each section 20 may be formed in a formwork 40 of a mould 14 that may, in accordance with the general desired shape/form of said section 20 to be cast, be generally elongate, or wider than it is long. The mould 14 shown in Figures 2-12, being a mould 14 so configured to form a hollow tapered cylindrical elongate member 10 of a tower, is itself preferably of a hollow tapered cylinder form. However, alternatively, it may have a different shaped overall form, such as prismatic, triangular or polygonal that may be non- tapered, or non-linear along its length. It may also be just part of such as shape such as arcuate or semi-circular.

Furthermore, the internal periphery of the mould 14 (and formwork 40 thereof) may have the corresponding/same or different shaped internal hollow periphery, i.e. circular, ellipse, triangular, square, octagonal, polygonal etc.

Preferably, the mould 14 is generally symmetrical about a central elongate axis 11, that will be collinear with the cast or form of the elongate member 10 being formed. Preferably the elongate axis 11 is substantially at or near horizontal. For example, the mould 14, which may resemble a tower 10 shape in accordance with the shape of the elongate member 10 formed therefrom, maybe lying on a horizontal surface such that the elongate axis 11 has an upward angle the same as the taper of the to be formed elongate member 10.

Each formwork section 40 is preferably separable from the adjacent formwork section 40. Each formwork section 40 may comprise of an inner shutter 41 and an outer shutter 44. The inner shutter 41 defines the inner face 22 of the section 20, whilst the outer shutter 44 defines the outer surface 23 of the section 20. Some formwork sections 40 may also comprise stop ends 42 placed at lateral ends of the formwork 40 that define the face end 31 (also herein referred to as outwardly facing end surface or surfaces) of the cast portion 20B of the section 20.

The volume defined by the formwork section 40 at the lowermost location thereof is segment 36. A suitable material, such as concrete, is able to be poured or pumped into the volume, such that a cast portion 20B of a section 20 is able to be formed from casting sequential multiple segments 36.

The inner shutter 41 may define only a length of an arc (creating a face) of the inner circumference of the inner surface 22 of the section 20. Whereas the outer shutter 23 is able to define the entire outer surface 23. Thus, the segment 36 preferably defines a circumferential arc of the periphery 26 of the section 20, extending from said arc longitudinally along the length of the section 20 to form said cast portion 20B thereof. As described earlier, to form (aka cast) the entire section 20, the formwork section 40 is rotated such that new segments 36B can be defined, preferably adjacent, the previously formed segment 36A. The formwork section 40 needs to be rotated in increments that add up to 360" to allow the cast portion 20B of the section 20 to be fully circumferentially formed/complete.

The formwork section 40, does not need to have an inner shutter 41 that extends around the entire notional inner circumference of the section 20 to be formed. Instead the inner shutter 41 may only define an arc of the total circumference of the section 20, as shown in Figure 16B. As such the inner shutter 41 can be smaller, lighter and cheaper than systems that require an inner shutter that defines the entire inner circumference of a section at one time.

For example, the inner shutter 41, may only define an arc of a 1/4 of the notional inner circumference of the section 20 to be formed. Alternatively, the arc defined may be between 1/16* and ½* of said notional inner circumference.

An example of the type of segments formable is illustrated by notional segment 36X as illustrated in Figure 17A. These segments 36X have a corresponding inner arc 30A equidistantly spaced apart from an outer arc 30B across the circumferential length of said segment 36X. In this instance, the inner shutter 41X would correspondingly have a bottom arc 42X that defines said inner arc 30A of the notional segment 36X to be formed. This example corresponds generally to cylindrical uniformly thick hollow sections 20 being cast, as also shown in Figures 1A-1D, 11A-11D and 16A-16B.

Alternatively, as shown in Figure 17B, the inner shutter 41 Y may be shaped differently to define a non-arcuate notional segment 36Y, such that rather than a bottom arc 42X, a linear or straight bottom periphery 42Y is provided for the inner shutter 41Y. This thus defines an inner edge 31 A that extends horizontally to intersect with an outer edge 31B of the notional segment 36Y. Dotted lines in Figure 17A-17B illustrate the relative shapes of the other segments 36X', 36Y' that will be formed when employing inner shutters 41X, 41Y as described.

Figures 17A-17B thus illustrate how the inner shutter 41 may be configured to suit different segments as desired. In Figure 17B for instance, configuring the inner shutter 41Y as such allows for a circumferential or circular outer edge of the section 20 so formed, with a pentagonal hollow interior defined by the inner edges 31 A of the segments 36Y thereof.

Those skilled in the art will envisage many other ways to configure the inner shutter 41 so as to result in different interior hollow configurations of a section 20 to be cast. In some embodiments, the inner shutter 41 may consist in multiple components so as to be taken apart in places to permit more complex shapes to be formed. For instance, part of the inner shutter 41 Y of Figure 17B will need to be removed prior to rotation to allow movement of a completed segment past the bottom periphery 42Y thereof.

In some circumstances the inner shutter may not be required. In the example shown in figure 17B the inner shutter is optional as the settable material will naturally settle in the outer shutter with a level top surface.

Whilst the segment 36X is in mathematical terminology perhaps better indicated as a sector of a circle and the segment 36Y is in mathematical terminally commonly indicated as a segment of a circle, for convenience these are both referred to as segments herein.

When circumferential segments 101 (as described further below) of seat members are employed instead of stop ends 42, said segments 101 may be sized to match the arc length of the segment of cast portion 20B of section 20 to be formed therebetween (as described later below, and as shown in Figure 16B).

Furthermore, the inner shutter 41 generally remains at the lowermost location of the mould 14/formworks 40 thereof. As the inner shutter 41 remains at a similar location throughout the moulding process, an already formed/cured/set/cast segment 36A must be rotated away from said lowermost volume defined by the inner shutter 41. This is achieved by the outer shutter 44 rotating along with rotating the cured segment 36A away from said lowermost volume defined by the inner shutter 41.

Once the outer shutter 44 has rotated, along with the respective cured segment 36A, a new volume is defined by the inner shutter 41 at the lowermost location of the mould 14 or formwork section 40 thereof, and a new pouring process of a new segment 36B can be performed.

Once this new segment 36B has cured, the outer shutter 44 and the cured segments 36A, 36B may be rotated again, to allow a new pour to be poured into the volume defined by the inner shutter 41. This is repeated until a fully formed/cast section 20 is created.

This process of rotation informing the methods described herein is shown in

Figures 1A-1D.

Additional detail can be seen in these Figures 1A-1D, such as ties 49 having been inserted after or during rotation to support the cured sections 36 as they are rotated past their lowermost point in the mould 14. These are required in embodiments where larger heights H of the section 20 means the segments thereof must be supported. The ties are commonly formed from steel bar or other conventional systems in the industry. Alternatively, or in combination, the formworks 40 may comprise cast in anchors or ferrules which are removeable. This allows the cast segments 36 to be anchored to the outer shutter 44.

Figures 11A-11D also illustrate the sequence of concrete pours. It can be seen that the sides 34 of the segment 36A is horizontal in the first pour, as shown in Figure 11 A. In the subsequent pours shown in Figures 11B-11D, the next segment 36B to be formed against the cured segment 36A, will butt up against the sides 34 of the previously formed segment 36A. As such the sides of the currently formed segment 36A will be vertical and co-planarthe sides 34 of adjacent segment 36B as shown in Figures 11B. This arrangement is shown progressing sequentially with each pour of each segment 36A-36D in Figures 11C and 11D. A benefit of this is the avoidance of captured air. Venting gaps along the inside top edge of the outer shutter 44 should be provided to allow air to escape while the concrete displaces the air during filling.

There may be multiple methods of relocating or maintaining the location of the inner shutter 41 at its same location as the outer shutter 44 is or has been rotated. One example may be that the inner shutter 41 is supported by rollers or wheels so that the inner shutter 41 always wants to maintain a location at its lowest point on an arcuate track and so is maintained at this location by gravity. External forces and/or movement may be required to "unstick" the inner shutter 41 from the cured segment 36. The inner shutter 41 may be manually moved or maintained at its lowermost location within the mould 14. The rollers allow the inner shutter 41 to move relative to the outer shutter.

As described above, since the inner shutter 41 preferably only forms a partial arc of the notional circumference of the section 20 being formed, it is much lighter, reducing handling time and costs as well as reducing costs in the provision of said smaller/segmented inner shutters 41, compared to an inner shutter that forms the entire inner circumference of the section 20.

Once more, as the entire section 20 is not poured at one time, the hydrostatic forces are significantly reduced forming only circumferential segment 36 at a time. As such the overall formwork 40 can be much lighter and less complex as the forces it must endure are reduced, thus reducing material, manufacturing and handling costs.

The outer shutter 44 assembled has a length L (as shown in Figure 12) that will form the intended lengths of each section 20. Each section 20 can be separated, removed from their formworks 40 of the mould 14 and re-joined back together with adjacent sections 20, or can be formed as a combined coupled unit within the mould 14 and removed together as a larger elongate member 10 formed therefrom.

To that end, the outside shutter 44 may be composed of a plurality of several smaller circumferential outer shutter sections 45 which when assembled form the outer shutter 44. The outer shutter 44 can be broken down into the outer shutter sections 45, as shown in Figure 3 to allow for subsequent removal, thus providing access into the mould 14 for removal of a completed/formed elongate member 10 (or section 20 thereof).

As an example, each outer shutter 44 may be divided into at least two parts by horizontal joints 46 (as shown in Figures 4 and 7) to form a lower outer shutter half 48 and an upper outer shutter half 47. Said upper outer shutter half 47 may be removed to permit access into the formwork 40 for removal of a section 20. Those skilled in the art will envisage various means of removing a completed elongate member from the mould 14. For instance, the upper outer shutter half 47 of all the outer shutters 44 of consecutive formwork sections 40 may be removed/lifted away from the mould 14, with the completed elongate member pulled or otherwise moved along its horizontal axis 11 out from either end of the mould 14.

Alternatively, outer shutter sections 45 or outer shutter halves 47, 48 of the outer shutter 44 may be removed, with the rollers 50 (as described below) upon which the remainder of the outer shutter 44 rests are actuated to roll and thus rotate the outer shutter 44 such that an opening so formed by removal of said section(s)/halves 45, 47, 48 is presented for lifting of the completed elongate member 10 or portion thereof out from the opening. Such a method may also be employed for removal of a single section 20 formed within a single formwork section 40, or even for separate removal of multiple sections 20 within a mould 14 for later re-joining together.

Further, said removal of sections 45 or halves 47, 48 of the outer shutter 44 may permit a reinforcement cage 25 or reinforcement rods 25 to be lowered into the formwork 40 by a crane or lifting device, as shown in Figure 4. After which, said sections 45 or halves 47, 48 of the outer shutter 44 can be reinstated into the formwork 40. Said cage or rods 25 may thus have settable material cast/poured therearound to become a permanent reinforcing feature of a section 20.

The rollers 50 that the outer shutter 44/formwork section 40 rests upon may be typically located at the end of each of the formworks 40. The rollers 50 may permit horizontal and/or lateral movement necessary when separating adjacent formwork sections 40 and sections 20 from each other (i.e., in instances where the sections 20 are removed separately from the mould 14, then rearranged/coupled together at later point). Lateral movement is shown in Figure 5, where a lifting/movement mechanism 62 is shown moving the formwork 40 laterally away to form a spacing 61 between an adjacent formwork sections 40.

In that case, the roller 50 may be provided an elongate axle, where the previous roller location is shown in dashed lines therealong, and the new roller location 53 is shown/indicated by solid lines on the formwork section 40 on the right-hand side of Figure 5. There may be numerous ways to slide a formwork section 40 and corresponding section 20 laterally. The moving of the formwork section 40 and corresponding section 20 allows a lifting mechanism to more easily remove a section 20 from the formwork section 40, so the section 20 does not interfere with the adjacent section 20 and formwork section

40.

Preferably the formworks 40 (and inner shutter 41, outer shutter 44, stop ends 42 thereof) are composed of metal, metal alloys and the like. Other materials may be employed such as wood, concrete, plastics and composites. The composition of the formwork 40 is known in the art.

A means for rotating the mould 14 (preferably the outer shutters 44 thereof) are located at intervals along the outer shutters 44. Preferably the rotation is provided by rollers 50, as described above. Each roller 50 controlled so that the correct speed is maintained at each of the rotating locations. This is preferably provided by gearboxes motors and a programmed controlling system.

In some embodiments, some rollers may be driven rollers 51, with other rollers being passive rollers 52, i.e. followers or guides, as shown in Figure 2. A skilled person in the art will be able to determine how many driven rollers 51 are required to rotate a mould 14 and its accompanying formworks 40. The rollers 50, 51, 52 comprise mounts 54 that support the rollers 50, 51, 52 on support surface/foundation 12, with each roller 50 preferably permanently anchored at the correct height and orientation to allow for horizontal/lateral movement or rotational movement of the outside shutters 44 thereon, as shown Figure 2. The rollers 50, 51, 52 may rotate one formwork 40 at a time, or all the formworks 40 of the entire mould 14 simultaneously. The latter is the preferred embodiment, so no interferences are created between relative movement of adjacent formworks 40 and cured segments 36 or sections 20 therein.

In one embodiment, the rollers 50 and/or roller mounts 54 are able to be adjusted in height to accommodate for any deviations in the ground level. Said height adjustment might be electronically controlled or monitored. The rollers 50 may be electrically/mechanically or hydraulically driven/actuated.

The rollers may comprise rotatable wheels or tracks (or any other means for rotatably supporting the mould 14 ) that are configured to engage with a corresponding track, gear, channel, groove, and/or guide located on the outer surface of the formworks

40.

Along with the inner shutter 41, the formwork section 40 further comprises stop ends 42 (as shown in Figure 6A) to prevent concrete flowing beyond the boundary or defined volume of the intended pour of a segment 36. The stop end 42 is not required on end matching pours, i.e. when a segment to be poured is intermediate of two already poured/set adjacent segments, for instance, as indicated by pours 4, 5 and 6 of Figure 6B.

The stop end 42 in one embodiment is L shaped, so that one side of the L forms the inner surface of the segment 36, and the other side of the L forms the end face 31. Once the segment has cured, the L stop end can be removed. The strip of the inner surface defined by the L can be used to bear a wheel of the inner shutter 41 against, so the inner shutter 41 can roll / move relative the respective cured segment 36. The inner shutter 41 may be required to jacked or wedged away from the inner surface of the segment 36 so it more freely moves relative to. The adjacent inner shutter will not require an L section stop end, as the end face of segment will be end face matched, however it may also comprise a removable strip formwork that once removed reveals a strip of inner surface for a wheel of the inner shutter to bear against. Shown in Figures 6A-6B is an embodiment method employing such stop ends 42 in a mould 14 comprising multiple formwork sections 40, the suitable material such as concrete when in a pourable condition, is poured in an alternative sequence to create segments 27, 28. For instance, shown in Figure 6A is the pouring (pours 1, 2 and 3) of odd-numbered segments 27 between inner shutters 41, outer shutters 44 and stop ends 42. Next, the stop ends 42 are removed, as shown in Figure 6B, and the even-numbered segments 28 are poured (pours 4, 5 and 6). Face end 31 matching is thus achieved at every interface (where the face ends 31 of adjacent sections 20 meet) when concrete is poured against the face end 31.

The concrete may be poured at the sides (i.e. the horizontal sides) 34 of the segments 27, 28, or alternatively or in combination, the concrete may be poured or pumped into an inlet 43 (shown in Figure 9) that is located in one or more of, the inner shutter 41, the outer shutter 44, and the stop ends 42.

Once the concrete in these segments 27, 28 has sufficiently set, such that a continuous length (along the elongate axis 11) of set concrete circumferential segments 27, 28 extend from end of the mould 14 to the other, release agent may be applied to the ends 42 of the cured segments 27, 28 preventing concrete poured adjacently from adhering to the ends 42. Temporary propping may be required to hold the cast cured concrete segments 36 in place.

The formwork 14 is then rotated (such as by rotation of the outer shutter/s 44 by rollers 50, as described above), before a next sequence of odd and even numbered pouring of segments is performed, the process repeated until the various sections 20 of the elongate member 10 being formed within the mould 14 are complete about their circumferences, i.e., a full 360-degree rotation of the mould 14 and formworks 40 thereof.

A gap may be left on the penultimate rotation to allow space for the concrete to be placed, filling this space is the last pour on the final rotation. Alternatively, pumping concrete via an internal gate valve or inlet 43 (as shown in Figure 9) may avoid this. Venting may be necessary to ensure that the concrete has flowed into all of the cavity that defines the segment 27, 28. The sequencing of the pours does not have to exclusively follow the above sequence. For example, by rotating the outer shutter 44 alternative pour areas can be accessed and a different pour sequence used. In an alternative example the entire sections 20 of the odd-numbered segments 27 may be formed, (i.e., pouring and rotating until they are full circumferentially complete) before subsequent pouring and rotating of the even- numbered segments 28 and thus completion of the corresponding sections 20 thereof. Or vice versa. Any alternative pour sequence also be can be used at the discretion of the user.

Once all the concrete inside the mould 14 has sufficiently set, the top outer shutter half 47 of each formwork section 40 may be removed, moved or opened and the sections 20 (individually or remaining as an assembly) can be removed from the mould 14.

Thus, when elongate member 10 is formed within the mould 14 with cast endmatching of adjacent sections 20 as described above, its subsequent extraction therefrom may take various different approaches. For example, removal may involve lateral separation of its formwork sections 40 and thus sections 20 formed therein (as shown and described above in relation to Figure 3), with each section 20 removed from its formwork 40 separately then later re-joined via means of the end-matching faces 31 thereof. Alternatively, the elongate member 10 may be removed from the mould 14 as a combined continuous length of adjacent sections 20, so as to be transported to site and then erected as required.

For subsequent use, the mould 14 may then be cleaned and release agent reapplied to the appropriate surfaces. Reinforcement steel preferably prefabricated into cages for location in each section 20 is positioned into the formwork sections 40, and the top outer shutter half 47 is replaced or installed. The manufacture of a second set of concrete sections 20 may then proceed.

The segments of a section are preferably cast against each other so that then abut and can form a continuous outer wall of the segment between its opposed ends. The segments of each section are hence are provided as an endless series about the elongate axis. The segments may be connected together to each other using Rebar or ties. A preferred type of concrete to be used as "High Slump" or self-compacting concrete. Self-compacting concrete is very transportable pre-curing and will find its own level when pumped between into the formwork sections 40.

Embodiments described thus far have predominantly focused on usage of shuttering that includes removable stop ends 42 for the longitudinal determination of the settable material into the desired lengths of circumferential segments being cast, as well as methods of casting multiple adjacent sections longitudinally based on notional sequential numbering (i.e., odd-numbered sections cast first then even-numbered sections etc.). However, in an alternative embodiment, seat members may be used as will be described hereinafter with reference to Figures 13-16B.

The seat members 100B1, 100A2 may each be unitary, having a full and continuous circumference (i.e., annular-like elements) as seen in Figure 16A or they may be assembled from circumferential segments 101B1, 101A2 provided at each end of a cast portion 20B of a section 20 as shown in Figure 16B. The seat members (whether unitary or segmented) become incorporated as part of a completed section 20 once formed and thus are not removed therefrom. Thus when seat members are employed, they define the lateral ends of the cast portion 20B of the section 20, and thus form part of the body 20A. By contrast, when stop ends 42 are employed, they also define the lateral ends of the cast portion 20B, but are removed later after casting and thus do not form part of the body 20A of the section 20.

The seat members are preferably formed from a settable material such as concrete. They are preferably formed by moulding.

These seat members, whether initially fully formed annular members as in Figure 16A, or successively added segments to incrementally become fully formed and continuous about their circumferences as in Figure 16B, may advantageously be used to end-match said section 20 with another to-be-casted adjacent section 20, so as to form an elongate member made up of stacked end-matched sections 20, by mating seat member pairs 100 together as will be described in further detail below. A seat member pair 100 may thus comprise of two seat members 100A1, 100B1 that are formed (e.g. cast) together as a matching pair. A seat member pair 100 may then be placed on ends of adjacent sections 20 to be mated. This helps ensure that sections are end matched thereby having a facsimile shape of mating surfaces to help ensure a structurally integral tower can be erected.

Further, by forming a permanent feature of the sections 20 being cast, the seat members do not need to be removed and thus may accelerate production processes. In some embodiments, the seat members may also comprise integrated features such as reinforcing bars, as described below, that may improve the structural integrity of the sections 20 and the tower or portion thereof produced therefrom.

Figure 13A shows an example means of which an embodiment seat member pair 100 may be formed. Said seat member pairs, or seat members 100A1, 100B1 typically take an annular ring-link form. Thus, a cross-section of a formwork 102 is shown in Figure 13A comprising an outer formwork 105, and inner formwork 107, between which is a void where a settable material such as concrete is to be poured to form said seat member pair 100.

Each seat member 100A1, 100B1 comprises matching mating faces 109A, 109B, that correspond to the interfacing split by which the seat member pair 100 is divided into said seat members 100A1, 100B1. On the opposing ends of each seat member 100A1, 100B1 are outward faces 111 A, 111 B that thus also define corresponding outward faces

111 A, 111 B of the seat member pair 100 itself.

During casting, the outer formwork 105 supports the cast pressure as a first load of settable material is poured into the void to form the first, or bottom-most seat member 100B1. Once that seat member 100B1 has cured and acquired sufficient strength, a release agent is applied to the 'top' surface (corresponding face 111 B) of said seat member 100B1, following which more settable material may be poured into said void for formation of the second seat member 100A1 on top of it. The release agent prevents the two seat members 100A1, 100B1 from sticking or bonding together with the lower seat member 100B1 acting as a 'pro-former ¹ to the second seat member 100A1 poured there-against, thus creating a matched cast fit.

It should be noted that while the Figures 13-16B may show the seat members 100A1, 100B1 as 'halves' of an associated seat member pair 100, when the term seat member is used throughout this specification, it should be understood to encompass any longitudinal portion of a seat member pair 100 i.e., any suitable or desired length of that seat member pair 100. Thus, a given seat member 100A1, may comprise a quarter, a half, a third, or any other longitudinal proportion of that seat member pair 100, with the other seat member 100B1 thereof comprising the remainder longitudinal proportion of that seat member pair 100, such that the two seat members 100A1 and 100B1 (or 100A2 and 100B2, 100A3 and 100B3, etc., as used further below, where the numbers 'χ' at the end of the reference numerals 100A'x' or 100B'x' thereof denote seat members of a given seat member pair 100) substantially form a complete seat member pair 100.

This matching cast fit provides the above-mentioned benefit of easily coupling together successive and adjacent sections 20 when assembling a larger elongate member or portion thereof.

One end surface of a seat member of a seat member pair is a negative of the end surface of the other seat member of the seat member pair (being the positive). This way when the seat members of a pair are in abutment in said elongate member their interface is such that loads are desirable transferred between sections of the elongate member.

Once the top seat member 100A1 is also cured, the seat member pair 100 can be removed from the formwork 102 and then split/sepa rated into the two seat members 100A1, 100B1 along said interfacing split/mating faces 109A, 109B thereof. Following which, (as is illustrated by way of example in Figure 14A) one seat member 100A2 is made to form part of a section 20X that is formed (using any of the methods described herein), and the other seat member 100B2 is made to form part of an adjacent section 20Y that is formed, the two sections 20X, 20Y then easily brought together by way of coupling of the match cast-fit of the respective mating faces 109A, 109B of their respective seat members 100A2, 100B2. It will be appreciated that in some embodiments, the seat members 100A1, 100B1 can be used to bring together more than just two individual sections, but instead can bring together two or more lengths of successive sections already coupled together. Said lengths may comprise, for instance, an already cast/formed length of tower elongate member 10 as described above, cast/formed using the previously described methods, or an already cast/formed length of tower elongate member 10 cast/formed using the below-described seat member method (in lieu of the stop ends 42 described earlier). In either case, two lengths of an elongate member can be easily coupled together by forming said lengths such that seat members 100A1, 100B1 of the same seat member pair 100 are arranged at adjacent ends of said lengths to be coupled.

Figure 14B shows such a length 200 comprising three sections 20. These sections 20 may have been formed individually, using separate formworks as described above, then bought together by coupling of corresponding seat members. Alternatively, they may have been cast together using an alternative embodiment of the casting methods described above, wherein instead of stop ends 42, seat member pairs 100 are employed and thus form part of the cast sections 20.

Said alternative embodiment of the casting method comprises, presenting a plurality of seat member pairs 100 each between notional end faces 31 of adjacent odd- numbered and even-numbered sections 20 to be cast. Said seat member pairs 100 being circumferentially complete annular-like pairs 100 cast as described with reference to Figure 13A. In this example length 200, sections 20' and 20"' may be said to be the notionally odd-numbered sections to be cast, with section 20" therebetween defining the notionally even-numbered section to be cast. Thus, two seat member pairs 100', 100" are placed between said sections 20', 20", 20'", with the outward faces 111 A, 111 B thereof placed adjacent said notional end faces 31 of said sections to be cast.

Thus, forming a length of segment of the odd-numbered sections 20', 20'" may be done by utilising formwork defined by an outer shutter, inner shutter and corresponding seat members 100B1, 100A2 for section 20', and seat members 100B3 and 100A4 for section 20'" via locating settable material into the formwork. Further, seat members 100A4, 100B1 are also of course placed at outward-most ends of said length 200, at the ends 31 of the odd-numbered sections 20', 20"' that will then go on to match with other lengths 200 having corresponding seat members 100A1 and 100B4 (not shown in Figure 14B).

Since the previously employed stop ends 42 are no longer present, and the seat member pairs 100 used instead form permanent features of the length 200 being cast, it is not necessary to wait for the odd-numbered sections 20', 20'" to be set or partially set before locating settable material into the even-numbered section 20", said even- numbered section 20" once more cast between by a formwork defined by an outer shutter, inner shutter and corresponding seat members of said seat member pairs (seat member 100B2 of seat member pair 100' and seat member 100A3 of seat member pair 100").

Like the previously described methods, once the odd-numbered and even- numbered segments are set or partially set, both the odd-numbered and even-numbered partially formed sections are simultaneously rotated about the central axis, following which the same casting sequence is repeated for the adjacent segments to be cast until the sections 20', 20", 20'" are fully formed and continuous about their circumference.

It will be appreciated that the above described details of formwork sections 40 (i.e., how the inner and outer shutters 41, 44 may be configured or arranged, how the formwork may be made to rotate the segments cast therein, how the shutters 41/44 may be taken apart for removal of completed sections 20 etc.), the configuration and/or arrangements of rollers 50 thereof, and the pouring methods and vents of casting methods described above, may all apply equally to 'seat member employing' embodiments.

Further, as described earlier, some embodiments may instead employ circumferential segments of seat member pairs rather than entire circumferentially complete annular-like pairs. Such circumferential segment seat member pairs may be cast as described similarly to the method of Figure 13A, however, as shown in Figure 13B, circumferential splitters 106 may be placed extending between the inner formwork 107 and outer formwork 105 to thus split each seat member 100A1, 100B1 into circumferential segments 101', 101", 101"', 101"". Any number of circumferential segments may be desired, so while four quarters are shown in Figure 13B other instances may require only 2, 3, 5, 6 etc. or any number of circumferential segments (i.e., may not necessarily be 'quarter' circumferential segments). Once each segments of the bottom-most first seat member 100B1 is set (with release agent applied to both faces of the splitters 106 to assist in their eventual removal), release agent may be applied to the combined mating face 109B of that seat member, before subsequent segmental casting of the upper seat member on 100A1 is performed.

In some embodiments, rather than casting the segments 101', 101", 101'", 101"", they may instead be formed more simply by cutting through circumferentially complete seat members 100A1, 100B1 (cast using the method described earlier with reference to Figure 13A) using tools suitable in the art.

Circumferential segments 101 of the seat members may be employed in instances where the elongate member (or section 20 thereof) to be cast/assembled is so large (i.e., diameters above 10 meters) that the pressures created by settable materials poured/cast into a formwork 102 for the seat member pairs 100 is such that irregularities and inconsistencies in casting are more likely to occur.

When employing circumferential segments 101 of seat members rather than full rings, as shown in Figure 16B, the method described above is substantially the same except that said circumferential segments 101B1, 101A2 are placed in between notional end faces 31 of adjacent odd-numbered and even-numbered sections to be cast rather than full seat members 100B1, 100A2, as shown in Figure 16A. Said segments 101 B1,

101 A2 may be sized to match the circumferential segments 36 of the sections 20 being cast. Thus, once a continuous length of segments 36 of odd and even numbered sections are set or partially set, the sections 20 are rotated about the central axis, after which the next circumferential segments of the seat member pairs are placed adjacent the previously presented ones, and the casting/pouring sequence is repeated thereafter.

Those skilled in the art will envisage various tying methods that may be employed to reinforce annular or circumferential connection between adjacent circumferential segments 101 B1, 101 A2, such as steel concrete ties and the like.

In some embodiments, a circumferential segment of a section once cast, with its corresponding circumferential seat member segments 101 B1, 101 A2 at ends thereof, may be removed from the formwork prior to casting of the adjacent circumferential segment. Thus, a plurality of circumferential segment lengths of a section may be consecutively formed and removed then tied or connected together along their circumferential or annular directions after being arranged as desired.

Figure 13A shows reinforcing bars 113, or rebar, extending from a location near the mating faces 109A, 109B of each seat member 100A1, 100B1 and out through said outward faces 111A, 111B thereof. Since casting of said seat members occurs on preferably a horizontal surface, holes may be provided within the surface as shown to provide space for the rebars 113 of the lower seat member 100B1.

These rebars 113 can be used to reinforce or strengthen the seat members 100A1, 100B1 (and/or circumferential segments 101A1, 101B1 etc. thereof) and may also help to increase tensile resilience of the sections 20 overall, since the rebars 113 will extend into the area of the sections 20 to be cast and thus the settable material poured when casting said sections or segments thereof is poured around the rebars 113.

In some embodiments, rebars 113 may extend across seat member pairs 100 and thus through the mating faces 109A, 109B thereof. Cavities may be formed around the portions of the rebars 113 that extend into the area where settable material is poured for formation of adjacent sections 20. Said cavity being grouted later to create continuity thereacross. Rebars 113 may be composed from steel dowels, or other know suitable metals, metal-alloys or materials having tensile capacity which compliments the compressive capacity of cast concrete and the like.

Figure 15A shows that the mating faces 109A, 109B of the seat members 100A1, 100B1 may in some embodiments be configured to have castellations 115 cooperating with corresponding apertures 117. This may be provided by reconfiguring the formwork 102 and associated method described above in reference to Figure 13A. These castellations 115 and corresponding apertures 117 will have sufficient draft or slope on the projecting surfaces thereof in order that they can be released from one another with-out damage to the seat members 100A1, 100B1. While Figure 15A shows said configuration employed on each circumferential segment 101 of the seat members 100A1, 100B1, it will be appreciated that said configuration can be employed in the casting of circumferentially complete annular-like seat member embodiments as well.

Figure 15B shows another variation of the seat member casting methods of Figure 13A. In this embodiment, a thickness of one of the seat members 100B1 may vary circumferentially so as to define a cross-sectionally tapered or wedge-shaped seat member 100B1. Further, as shown, the thickness of both seat members 100A1, 100B1 may vary circumferentially.

In this way, a seat member pair having at least one cross-sectionally tapered wedge-shaped seat member has a bend at the interface (mating faces 109A, 109B) between said wedge-shaped seat members and the other corresponding seat member (whether also tapered or not) of the seat member pair. Thus, said bend of said seat member pair is such that the central axes 20X', 20Y' of the sections 20X, 20Y cast adjacent the opposite outward ends 111 A, 111 B of said seat member pair are orthogonal with one another i.e., not coaxial/in-line, as shown in Figure 15C. Thus, elongate members may be assembled having bends or changes in direction, which may be particularly beneficial when assembling the elongate members of a road tunnel, for instance.

In some embodiments, the mating face 109A of one of the seat members 100A1 of a seat member pair may comprise male alignment guides configured to cooperate with female alignment guides of the other seat member 100B1 thereof. This may help with coupling together of said seat members of a seat member pair 100.

It should be noted that the term elongate member is intended to encompass members having tapered, frustoconical or conical shapes, and that the above described seat members 100 and methods of casting thereof may be configured to suit such shapes. For instance, the seat members 100A1, 100B1 and seat member pairs 100 may comprise longitudinally tapered structures to suit a tapered (conical) section 20 to be formed.

It should be further noted that while the seat members described herein are shown in the Figures as being annular/circular in formation to correspond with the hollow cylindrical or tapered tubular shape of a preferred elongate member or tower 10 so formed thereby, the seat members may also take other shapes/forms depending on the shape/form of the corresponding section of the elongate member. For instance, they may be polygonal, hexagonal, octagonal etc., or any other non-circular peripheral shape or form, with a correspondingly-shaped, or even a differently-shaped, hollow interior periphery.

Using seat members provides a low-expense means of forming elongate members having bends or that are not straight, by employing tapered or wedge-shaped seat members described in relation to Figures 15B-15C. Further, the lack of a need to remove stop ends 42, and instead simply rotating seat members with the segments 36 during casting, speeds up the casting process and may help in automation thereof via synchronised control of rotation of the sections (via rotation of formwork 40, i.e., rotation of the outer shutter 44, as described above), via, for instance, motors 500 engaging with the outer shutter 44 for rotation thereof, as shown schematically in Figures 16A-16B.

The interfacing match-cast fit of the mating faces 109A, 109B (presented as outward facing surfaces of respective section) of each seat member pair 100 also allows fast assembly, and thus faster 'just-on-time' casting and assembly of elongate members or portions thereof. Larger diameter elongate members may also be achieved using said seat members without having to use longitudinal joints extending across sections. It should be noted that in some embodiments, at an end of a mould/formwork 14, whether it comprises a single formwork section 40 (and is thus being used to cast a single section 20) or whether it comprises a plurality of formwork sections 40 (for formation of multiple sections 20 of an elongate member or portion thereof), a component may be placed at either or both outward-most ends of said mould/formwork 14 other than (or in combination with) a stop end 42 or seat member 100A1/100B1.

Such a component may comprise, for instance, a cast or pre-assembled bulkhead 700 as shown in Figure 18 (such as for the foundation of a tower or other supporting structure), a slew ring 702 or other mechanical/actuation/transmission feature (such as for the top-most tower section of a wind turbine, where said slew ring couples to the nacelle 704 of a wind turbine), a truss structure (such as for connection to the larger truss section of a structure to be supported etc.) and the like. Those skilled in the art will appreciate the various modification or additions that may be made to the formworks/moulds described herein to suit the particular application of the elongate member being formed.

Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth.

Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope or spirit of the invention.