The invention is related to the construction of a concrete cross beam from crossbeam segments on a sheet-pile wall to form a quay wall, and to a shell structure for the application of the cross-beam-forming material in pieces or segments with an intermittent pattern.

Quay walls are retaining structures for ships to berth. For its protection, the quay wall, is equipped with a cross beam, which cross beam partly extends into the water. In general, the pillar can also be equipped with bollards to moor ships and if need be with fenders to absorb shocks. In literature, cross beams can also be referred to as gantry girder or ridgepole.

Prior art shows us two important methods for manufacturing such cross beams, namely by means of protection walls or by the use of prefabricated elements. In case of important water depths, protection walls are unsuitable and uneconomic. Prefabricated elements give rise for corrosion of the front wall and further modifications are expensive or no longer possible.

The invention aims to solve these problems and thereto provides a method for the forming of a cross beam at a sheet-pile wall in order to get a quay wall, in which the complete cross beam is composed by cross-beam segments. The sheet-pile wall partly extends over the water surface and preferably, it is composed of tubular poles or H-sections with sheet piles in between. Subsequently, cross-beam-forming material is applied against the sheet-pile wall by means of a shell structure shoring up against the sheet-pile wall. This shell structure is pressed against the sheet-pile wall from the water side and subsequently equipped with a curing cross beam material. It goes without saying that for a good sealing, the shell structure and the sheet-pile wall are necessary. For this purpose, this shell structure is executed at least partially of equal form with the sheet-pile wall. By fixing a shell structure from the waterfront against the sheet-pile wall by means of a pontoon or barge, equipment such as cranes and alike on the land side become unnecessary. The cross-beam segments are preferably applied to the sheet-pile wall in an intermittent pattern. Intermittent pattern means that a next cross-beam segment is not mounted directly on a foregoing cross-beam segment, but that between the cross-beam segments, a free length is left for a cross-beam segment that is preferable slightly smaller than the length of the shell structure. Between the two previously fixed cross-beam segments, subsequently another cross-beam segment is applied. In a preferred embodiment, the cross-beam segments are applied in an odd pattern 1, 3, 5 etc. and then subsequently the further even cross-beam segments, namely 2, 4 etc. which are placed between the cross-beam segments 1 and 3, 3 and 5 etc.

In a preferred embodiment, a method according to the invention for mounting a cross-beam to a sheet-pile wall for obtaining a quay wall, wherein the cross beam is composed of cross-beam segments comprises first placing a sheet-pile wall in the water, which partially extends above the water surface and preferably is compiled from tubular poles and sheet piles mounted between the tubular poles in a regular pattern, after which cross-beam forming material is applied against the sheet-pile wall by means of a shell structure which supports against the sheet-pile wall, mounting the cross-beam segments according to an intermittent pattern to form a full cross beam.

In order to procure an adequate seal between the sheet-pile wall and the shell structure, the shell structure is first pressed against the sheet-pile wall, preferably by means of a pontoon, after which the shell structure is already temporarily firmly mounted to the sheet-pile wall, before it is provided with curing cross-beam material. For this purpose, the shell structure is preferably equipped with anchoring legs, which are adjustable in length, and which extend from the shell structure to their position against the sheet-pile wall. These legs are fixed to the quay wall with heavy axes via vertical sections (through the wall of tubular poles) or with lateral welds against the tubular pole. This invention also relates to a quay wall consisting of a sheet-pile wall on which cross-beam segments are applied according this method.

This invention also relates to a shell structure for the forming of the cross-beam segments at a sheet-pile wall consisting of an upper partial structure of a formwork construction provided with a back wall, two sidewalls and a floor suitable for receiving the cross-beam forming curing material and a lower partial construction for supporting the shell structure on the sheet-pile wall.

In a preferred embodiment the shell structure suitable for the forming and mounting of cross-beam segments to a sheet-pile wall consists of two box-shaped partial constructions, namely an upper partial construction suitable to receive a cross-beam forming curing material and a lower partial construction for the supporting and temporary fixing of the shell structure on the sheet-pile wall.

The support of the shell structure is obtained by means of a specific substructure, in order to achieve an almost watertight seal.

Preferably, the floor of the lower partial construction is provided with an open floor edge which is of equal form to the sheet-pile wall. For this purpose, the sheet-pile wall has to be built according to a precise and regular pattern. Preferably made from among each other parallel tubular poles, between which a sheet-pile wall is provided. According to the invention, the shell structure is preferably provided with projecting and mainly among each other parallel sections with legs that are adjustable in length. These legs are extended up to their position against the sheet- pile wall, and that preferably via vertical sections and heavy axes led through the wall of tubular poles, in order to already establish a temporary fixed connection of the shell structure to the sheet-pile wall.

In a preferred embodiment, a shell structure according to the invention is characterized in that under the floor of the upper partial construction in the lower partial construction mutual parallel profiles are mounted, provided with anchor legs that are adjustable in length. In a preferred embodiment, a shell structure according to the invention, suitable for the forming and mounting of cross-beam segments to a sheet-pile wall, consists of two box-shaped partial constructions, namely an upper partial construction suitable to receive a cross-beam forming curing material and a lower partial construction for the supporting and temporary fixing of the shell structure on the sheet-pile wall. Preferably, the shell structure is provided with a seal joint on its edge, where this edge is foreseen to support at the sheet-pile wall, whereas the seal joint, in cross- sectional view, has a triangular shape. It has been established that such a shape offers advantages with regard to the sealing capacity.

In order to be able to realise the intermittent pattern with one and the same shell structure, the latter is provided with removable panels mounted in the sidewalls of the upper partial construction. Preferably the removable panel is attached in the open corner of each sidewalk Preferably the panel is of square or rectangular shape.

For an easy movement of the shell structure, it is provided with pairs of provisions for the forks of a forklift, and the corresponding forklift is provided on the pontoon. In a preferred embodiment a cross beam or cross-beam segment according to the invention is obtained by means of a shell structure according to an embodiment of the invention.

Finally, the invention is also related to a pontoon for the moving of the shell structure on the water, for which the pontoon is provided with a counterweight at one side and of one or more forklifts with forks on the other side.

A preferred embodiment of the invention is further discussed in detail below using drawings, in which the preferred embodiments of the invention are shown and in which is shown :

Fig. 1 A perspective and partial split view of the combination of a sheet-pile wall, the shell structure and the pontoon, according to the invention;

Fig. 2 Top view of Fig. 1;

Fig. 3 Cross-sectional view of a pontoon with a shell structure lifted by the forks of the forklifts, according to the invention;

Fig. 4 Schematic cross-sectional view of a shell structure, according to the invention;

Fig. 5 Perspective view of a shell structure, according to the invention;

Fig. 6a and 6b Detail of a preferred embodiment of the legs adjustable in length, the vertical sections and the connection through a tubular pole;

Fig. 7 Perspective view of a preferred embodiment of a seal, according to the invention;

Fig. 8 Perspective view of a pontoon, according to the invention;

Fig. 9 Perspective view of an intermittent pattern of the cross-beam segments in order to obtain a cross beam; and Fig. 10 Views of a floor shuttering.

In the construction of a quay wall 3, according to the invention, first a sheet-pile wall 2 is placed between the landside 5 and the waterside 4. Such a sheet-pile wall is preferably erected in vertical position according to a regular pattern of tubular poles 8 and fixed to the sheet piles 9 that are situated between the tubular poles 8. Such sheet-pile walls 2 are known from the prior art and they provide an almost watertight barrier between the landside 5 and the waterside 4. Subsequently, anchor piles 36 can be firmly fixed which normally extend above the sheet-pile wall 2. Firstly a partial soil supplement can be carried out on the landside behind the sheet-pile wall 2. Against this sheet-pile wall 2 and partially floating on the water, a shell structure 13 is pressed. The shell structure 13 serves as a temporary and reusable working and boxing platform for the cross-beam segments la. The shell structure 13 consists of two partial constructions, namely an upper partial construction 14 and a lower partial construction 15. The upper partial construction 14 is provided with a floor 16 with a floor edge 17 on which a formwork 11 and the cross-beam forming material 10 is provided for. The lower partial construction 15 provides for a substantially watertight connection with the sheet-pile wall 2. For this purpose, the subfloor 32 is provided with the subfloor edge 33. This subfloor edge 33 is provided as form matching to the sheet-pile wall 2. A pontoon 30 is provided with a counterweight 31 and forklifts 29 push - in operational condition - the shell structure 13 against the sheet-pile wall 2 and are able to finely position the floating shell structure as well in the vertical as also in the horizontal direction, as it is known from the operation of forklifts.

The upper partial construction 14 is executed in a box-shaped form and wider than the lower partial construction 15. The upper partial construction 14 mainly serves as workspace. Both partial constructions are executed in a box-shaped form and are each provided with a back wall 22a, 22b; two sidewalls 23a, 23a' and 24a, 24a' and a floor 16 and 32.

At the top, the lower partial construction 15 is bounded by the floor 16 of the upper partial construction 14 and on its underside by a subfloor edge 33 of a form executed as form matching with the sheet-pile wall. This lower partial construction 15 is used as a functional unit for support and seal for the shell structure 13 against the sheet-pile wall 2. Anchoring legs 19 are provided parallel to and just under the floor 17 of the upper partial construction 14. These anchoring legs 19 can be adjusted in length and extend from the shell structure 13 up to their position against the sheet-pile wall 2. These legs 19 are fixed in vertical sections 18 to the quay wall 3 by means of heavy axes 20 led through the wall made of tubular poles 8 with side weldings against the tubular pole 8. In a preferred embodiment of the invention, there are two anchoring legs 19 per tubular pole 8 provided for in a mirror symmetric manner on or in the wall of the tubular pole. In some places, they are preferably welded to the tubular poles 8. For these purpose, the ends of the legs 19 are provided with a vertical section 18 and a stop 34. The distance calculations which are carried out in advance provide a specific length for each leg 19 so that afterwards, only minimal adjustments are necessary.

The entire circumference of the lower partial construction 15, there were a watertight seal is desired, is provided with a sealing profile 24. In a preferred embodiment, this sealing profile 24 is triangular in cross-sectional view. The rubber joint 24 has a triangular profile with a total thickness of about 30 cm. This large thickness is necessary to be able to connect anywhere on the sheet-pile wall 2, taking into account the possible tolerances in the longitudinal and traverse sense. The rubber profile is both bonded and mechanically fixed in a UPN profile that consequently must follow the form of the sheet-pile wall 2, thus it is partially lobately bent. After the shell structure 13 is suspended on the sheet-pile wall 2 by means of anchorage of the anchoring legs 19 to the tubular poles 8, this shell structure 13 is pumped empty. Subsequently, the upper partial construction 14 is provided with curing cross-beam material 10 in a formwork 11 provided of a specific floor shuttering 34. The floor shuttering 34 is executed as form matching with the sheet- pile wall. Between the floor 16 and the slab formwork, possibly a lifting element 35 can be provided for. It goes without saying that the position and height of the cross-beam segment la to be applied must be very exact. The curing cross-beam material is normally made of armoured 12 concrete.

As an example, the shell structure 13 is constructed from a steel framework with a length of about 24m, a height of 6.00m and a maximum width of 5.20m. The steel framework is made from standard sections and panels of, for example, 6mm in thickness.

The upper wider partial construction 14 is the workspace with space for a crossbeam segment la, the slab formwork 11, the staff and further necessary material. The lower partial construction 15 should only be accessible in possible cases of emergency or for the control of the anchoring legs 19, the rubber joints 24 and the slab formwork 11. This lower part 15 also provides the necessary driving horizontal water pressure in order to press in the rubber joints 24 at the bottom without further help of mechanical fasteners and with minimal intervention from divers. Besides the two access points to the lower level of the ends, there is an extra access point 37 placed centrally through an oblique tube provided with steps. In the shell structure, there is a removable floor shuttering 34 with plastic sheeting onto which the concrete cross-beam la can be placed and which can be adjusted in height and in transverse direction by jacks via a lifting element 35. This floor shuttering 11 is constructed from six modules.

In a preferred embodiment, a shell structure according to the invention is characterized in that the width (br) of the lower partial construction 15 is smaller than the width (BR) of the upper partial construction 14, and is preferably smaller than half of the width BR of the upper partial construction 14.

In the shell structure 13, a floor shuttering 34 is provided as mentioned previously, positioned against the sheet-pile wall 2. This consists of six independently working modules 34a up to and including 34f. On the other side (waterside 4), there is a walking path 38 provided for the personnel, which is accessible from the mainland (landside 5) via gangways.

There are pumps for water reduction and leakage water placed on the lower part 15 of the shell structure 13. In this compartment, also welding can be done, and for safety reasons, adequate lighting is to be present. This area is always accessible from the ends of the shell structure 13. Because of the long escape routes, a central emergency exit has been chosen via an oblique tubular profile with steps.

The pontoon 30 is for carrying and moving the shell structure 13 to another position and for pushing it against the sheet-pile wall 2. For this purpose, the pontoon 30 is equipped with two symmetrically arranged lifting frames which are executed as forklifts 29. In the first place, the pontoon 30 must have sufficient buoyancy in all situations. During the manipulation of the shell structure 13, also the cross slope will change due to an increased charge at the front side (landside 5). For this, the shell structure 13 is equipped with provisions for receiving the forks 28 of the forklifts 29. In a preferred embodiment of a shell structure according to the invention, the shell structure is characterized in that the shell structure is provided with at least one and preferably of two or more means 27 for the reception of the forks 28 of a forklift 29 of a pontoon 30. In order to compensate this, a tilting frame is provided that can rotate by means of jacks. Then, in this tilting frame, a lifting frame (fork) is provided which in turn is able to move vertically by means of jacks. It is also possible to present the shell structure 13 at correct height and with the correct rotation in front of the sheet-pile wall 2, before fixing the elements against each other. The pontoon itself is composed of floating containers (flexifloats) which are compiled to one pontoon. Behind it, there is also a smaller pontoon 31 which is connected to the latter by a steel frame. This way, a catamaran type is created that provides a stable structure. On the smallest pontoon 31, also a small crane is placed for the manipulation of small material and a yard container. It active state, the floating pontoon 30 comes floating with the shell structure 13 on its forks 28. Subsequently, this shell structure 13 is fixed with the anchoring legs 19 to the sheet-pile wall 2. Then, water is pumped out of the shell structure 19. For the following steps, this pontoon 30 will provide for the repeated warping of the shell structure 13 and so a mobile crane is no longer needed. After the water has been pumped out, the floor shuttering 34 is adjusted to the correct height and a wall formwork is mounted. The pumps remain working constantly to be able to drain the infiltrating leakage water. The concrete cross-beam is then constructed from cross-beam segments la, which added in an intermittent way. First the odd segments la, 3a and then the intermediate segments 2a. As an example for a quay wall 3 according to the invention, this is built from crossbeam segments with a length of about 20m. Each segment consists of a sheet-pile wall of 6 tubular poles 8 and intermediate sheet piles 7. The cross beam 1 we get has a width of 4m and a height of about 3.5m. This cross-beam construction is anchored to the rear ground with anchor piles 36. The given dimensions are of course not limiting the invention.

The special aspect of this invention is that the cross-beam segments la, 2a, 3a are executed alongside the waterside 4, from the water in an essentially watertight closed shell structure 13, which is suspended at the sheet-pile wall 2. Moreover, this shell structure 13 is able to bear the full bulk weight of the curing cross-beam material 10, for example concrete, and consequently functions as a formwork at the same time. The cross-beam segments la, 3a are intermittently executed, during which preferably frequently one cross-beam segment 2a is skipped. Afterwards, the intermediate cross-beam segments are executed with a custom shell structure 13. The warping of the shell structure 13 to a next crossbeam segment is done with a floating pontoon 30.

For the intermediate segments 2a, the shell structure 13 is somewhat modified. At the open corner 26 of the sidewalls 25a on the upper partial construction 14, a removable panel 39 is mounted. For the cross-beam segments 2a, namely those that are mounted after the cross-beam segments la and 3a, the panels 39 are removed from the sidewalls. Thus it is possible to mount as well the first odd crossbeam segments la, 3a, etc. as also the intermediate even cross-beam segments with one single shell structure.