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DESCRIPTION

Field of the invention

In its most general aspect, the present invention falls within the technical field of construction. More particularly, the invention refers to a device for removing at least one part of excess material, in particular of piling or other cast-in-place manufactured articles.

State of the art

In the construction sector, when in the past there was the presence of soils with low mechanical resistance or when there was a need to make foundations for stress loads of considerable magnitude, the type of foundation most commonly used was the wooden pile, specifically of particular hard and resinous species, such as oak, durmast, etc.

This system has evolved over time, by adopting more and more performing and less expensive modes or pile-driving machinery and materials. Currently, the piles, in particular those with a small diameter called micro-piles, are made of metal; alternatively, the piles can be made of reinforced or nonreinforced concrete, since this material allows indirect foundations to be made for stress loads of considerable magnitude.

Both reinforced and non-reinforced concrete piles are particularly used, since they can be of any diameter. Normally, for various operational or design needs, once cast, the piles must undergo a removal of their head, i.e. of the part of the pile facing upwards; this type of working, which is common in the construction sector, is defined pile cropping.

Usually, the pile cropping must be carried out because the extrados height of the pile made is at a higher level than that in the final design of a building. In fact, most of the machines that form the piles, such as Continuous Flight Auger machines, CFA, FDP, etc., must work on a level surface, since it is not possible to dig holes to position the same machine. Often, the springing level of the foundation is at a level much lower than the height of the ground on which the machine works, also called the crawler height. For operational reasons, however, e.g. for the insertion of a reinforcement cage, it is necessary that the concrete be cast up to crawler height to prevent, when extracting the auger of the machine that carries out the hole, the surrounding ground from collapsing inside the same hole, thus no longer allowing the subsequent insertion of the reinforcement cage.

Since the piles usually have diameters ranging from 30 cm to 150/180 cm and the necessary lowering can vary from a few tens of centimetres to 200/300 cm, it is clear that the material to be removed for each pile can be quite a lot.

Currently, the removal, or cropping, operation of the head portion of the pile takes place with the following techniques:

- manually by operators using demolition hammers or demolition compressors;

- by means of mini-excavators equipped with demolition hammers;

- in particular for piles of medium to large diameter, by using a system called pile breakers, which comprises a crown of demolition jacks of considerable weight and encumbrance and arranged perimetrically with respect to the pile and kept suspended by using a large excavator (about 30000 kg); or

- other demolition systems, such as grippers and the like.

Therefore, the current systems have the following disadvantages:

- a waste of material, in particular concrete, which is unnecessarily used and then crushed;

- the formation of considerable quantities of rubble to be disposed of;

- a potential, often serious damage to the reinforcement cages of the pile head, which must then be repaired or replaced as they are essential for the connection to a foundation plinth which must be laid above the same pile; - the possible compromise of the full efficiency of the foundations, if the repair working of the above cages is not carried out accurately;

- the exposure of at least one operator to strong vibrations, high noise levels and various hazards of potential injury from crushing by large portions of rubble, inhalation of dust, etc.; and

- quite long working times.

The disadvantages described above also entail considerable costs for carrying out such working.

The document CN 112 012 210 A relates to a device for breaking the head of a concrete pile of a foundation which comprises an extractable cylinder, a sealing assembly and an actuating assembly. The lower end of the extractable cylinder is inserted into the foundation concrete before the initial setting. The sealing assembly is hinged to the lower end of the extractable cylinder. The actuating assembly is arranged on the extractable cylinder, is connected to a sealing assembly and is used to rotate the sealing assembly around a hinge point, so that the sealing assembly seals the lower end of the extractable cylinder. When inserting the extractable cylinder, the concrete can enter the extractable cylinder. Subsequently, the sealing assembly is actuated by the actuating assembly in order to rotate around the hinge point to close the lower end of the extractable cylinder which is then raised to remove the concrete contained therein.

Disadvantageously, such a system provides that the sealing assembly is closed by means of an actuating assembly which is particularly complex. In addition, the forced closing of the sealing assembly from the bottom upwards can be particularly difficult given the weight and consistency of the concrete which hinder its movement.

Summary of the invention

It is an object of the present invention to provide a device for removing construction materials, having structural and functional characteristics such as to overcome one or more of the drawbacks mentioned above with reference to the prior art.

Another object is to provide a device which allows to remove the excess material in a short time and with small costs.

A further object is to provide a device which allows to recover and reuse the removed material.

In accordance with the invention, the aforesaid problem is solved by a device for removing fluid, liquid, molten, dissolved material, or in any case not in a solid state, to be inserted and extracted into/from the fluid material, comprising a hollow body, which is open at two opposite ends, and closing means combined with one of the two ends to close it so as to define, with the hollow body, a containment compartment to contain the material to be removed and to open such end to allow the material to enter the hollow body, wherein the closing means can be moved between a closed position and a first open position, which are thrust directly by the fluid material entering the hollow body when the device is inserted into the fluid material and vice versa between at least the first open position and the closed position, thrust directly by the fluid material contained in the hollow body when the device is in the fluid material and is extracted therefrom. Advantageously, in the first open position, the closing means are at least partially inserted in the hollow body.

In other words, in accordance with the present invention, the aforesaid device comprises a hollow body, preferably a tubular body with circular section, and means for closing or opening one of its ends during its use and, specifically, for opening such end, during the step of inserting the same device into the material, and for closing it during the step of extracting the same device from the material, wherein the closing means are coupled to the hollow body by fastening means configured to allow their opening by means of the hydraulic thrust of the material entering the hollow body during the step of inserting the device into the same material, and their closing by the hydraulic thrust of the material contained in the hollow body during the extraction of the device.

Advantageously, the end that can be closed is the one intended to be inserted first, if both are inserted, or in any case to be inserted into the material to be removed.

In practice, in accordance with the invention, the aforesaid device allows to collect fluid or liquid phase material from a cavity, in particular to remove excess concrete before its solidification, in a simple but effective manner. The device is in fact structured to open its end automatically during its insertion into the material and to close it automatically during the extraction from the same material, without requiring any type of actuating means to bring the closing means into the closed position. This allows to have a very simplified, robust and efficient device, unlike the devices that require actuating systems in order to close the device, which have a complex structure and which can be prone to frequent malfunctions and breakages. In particular, the devices in accordance with the prior art provide that, in the open position, the closing means are arranged outside the hollow body and, thus, not only require actuating means for carrying out the closing but they can be prone to breakages of those actuating means since, during the closing step, the closing means must be dragged upwards, thus counteracting the high friction and the high weight of the fluid material in which they are immersed. It should also be noted that closing/opening control means immersed in concrete which, according to the design directives of the building to be built, can have various densities and whose inside contains gravel and other aggregates of various diameters, are certainly prone to stresses, frictions, pseudo-gluing phenomena and jamming phenomena absolutely unpredictable with aggregates; such a drawback, on the other hand, does not occur with a system of the type object of the present invention, which is in the form of a valve that opens automatically during the insertion step and closes automatically during the extraction step, without requiring any control means.

Usually, the insertion in the material takes place from the top downwards, vertically or in any case obliquely, whereas the extraction takes place from the bottom upwards and, therefore, the closable/openable end of the hollow body is the bottom end.

Advantageously, the fastening means are configured to allow a partial rotation of at least 45°, preferably of at least 60° and even more preferably of about 90°, in a first direction of the closing means with respect to the closed position, to allow the material to enter, and a return rotation to return to the closed position, to hold the material.

Even more advantageously, the fastening means are configured to allow also a partial rotation of the closing means, or of part thereof, of at least 45°, preferably of at least 60° and even more preferably of about 90° with respect to the closed position, in a second direction opposite said first direction, to allow the device to be emptied once the material has been collected, as well as a respective rotation to return to the closed position.

Preferably, the fastening means comprise at least one hinge combined with the hollow body.

Even more preferably, the closing means comprise a swing check valve, preferably of the clapet type, which can have a single plate or two or more plates.

Advantageously, at the closable/openable end, abutment means and/or locking means are formed for preventing the closing means from rotating in the second direction, due to the weight of the material contained in the hollow body.

Preferably, the abutment means and/or the locking means can be moved, e.g. by means of control means, to be able to be displaced to a position in which they do not interfere with the closing means, in order to allow their rotation in the second direction, so that they can open, preferably by the weight of the material collected, to allow the device to be emptied.

Advantageously, the control means can comprise levers and cables, which force the rotation of the closing means in the first open position, when the device contains the material to be removed, in order to empty it.

Alternatively, the control means are combined with the locking means to displace them, once the material has been collected, so as to allow the closing means to move to the second open position, thus unloading the material.

Advantageously, the hollow body can comprise an openable side portion combined with locking elements that keep it normally closed but which allow it to be opened when necessary, in order to empty the device.

Advantageously, the device comprises a supporting and attaching portion so that it can be fastened to movement means.

Preferably, the second open end has a narrowing flared portion with respect to the section of the hollow body to facilitate the insertion of the device into the material.

Even more preferably, the hollow body has at least one side opening preferably formed in an upper portion thereof, i.e. opposite the closable/openable end to facilitate the entry of the material and to allow it to be emptied.

Brief description of the figures

Further characteristics and advantages of the invention will become clearer in the review of the following detailed description of some preferred, although not exclusive, embodiments illustrated by way of non-limiting example with the aid of the accompanying drawings, in which:

- figure 1 schematically shows a top perspective view of a device for removing material according to the present invention;

- figure 2 shows a bottom perspective view of the device of figure 1 , provided with a valve in a first condition;

- figure 3 shows a side view of the device of figure 1 ;

- figures 4a, 4b and 4c show top perspective and views in partial transparency of the device of figure 1 in three different conditions of use;

- figure 5 schematically shows a top perspective view of a second embodiment of a device for removing material according to the present invention;

- figure 6 shows a bottom perspective view of the device of figure 5 provided with a valve in a second condition; - figure 7 shows a side view of the device of figure 5;

- figures 8a, 8b and 8c show top perspective and views in partial transparency of the device of figure 5 in three different conditions of use;

- figures 9a and 9b schematically show a top perspective view and a side view of a third embodiment of a device for removing material according to the present invention in two different steps of use; and

- figure 10 schematically shows a top perspective view in partial transparency of a fourth embodiment of a device for removing material according to the present invention.

Detailed description of the invention

With reference to figures 1-10, a device for removing non-solid material is generally denoted by 1.

The device 1 essentially comprises a hollow body 2 open at two opposite ends. Preferably, the body is tubular and has a first open end 3 and a second open end 4.

At or in the proximity of the second open end, closing means 5 are combined, which are constrained to the hollow body so that they can be moved at least between a first open position A, in which the second open end 4 is at least partially free and in which the closing means are at least partially, but preferably completely inside the hollow body - as shown e.g. in figures 4a and 4b - and a closed position B in which the second open end 4 is closed, thus preventing any material arranged inside the hollow body from coming out therefrom - as shown e.g. in figures 4c and 8c. Thus, when closed, the closing means define, together with the hollow body, a compartment 6 for containing the material to be removed.

Preferably, the closing means can also be brought to a second open position C, in which the second open end 4 is at least partially free, with the closing means arranged in a position different from the first open position, as shown e.g. in figures 8a and 8b.

Preferably, the closing means are in the form of a mobile valve and even more preferably of the clapet type, which comprises fastening means 7 to the hollow body, preferably in the form of a hinge to allow the valve to rotate by + 90° and possibly by - 90° with respect to the closed position in order to move to the first open position A or to the second open position C, respectively.

The figures show a valve constrained to the hollow body at a single point but the valve could be constrained at two points and rotate on its central axle, or else it may have two half-portions which can be moved independently of each other.

In order to keep the closing means closed, abutment means 8 can be combined with the hollow body to stop the closing means in the desired position and to avoid an undesired opening of the closing means toward the second open position, due to the weight of the material contained in the device and the coming out of the material contained in the same device.

The hollow body can vary in dimensions, depending on the size of the piles from which material is to be removed. In the case of a tubular body, the diameter can vary between 15-20 centimetres up to over 1 metre. In any case, the diameter must be smaller than the inner diameter of the reinforcement cage of the pile in which it is to be inserted, in order to remove the excess material. The height can also vary from a few tens of centimetres to more than 3 metres, depending on the volume of concrete that needs to be removed.

The device described above is used to remove fluid, liquid, dissolved material or in any case before its possible solidification or hardening step. Specifically, the device is particularly suitable for removing fluid phase concrete, or other materials used in construction, but also for removing water or other liquids, and operates as follows:

- the device is inserted into the material before its solidification, in particular in the concrete, with the closing means kept open, so that the concrete and, in general, the material can enter the hollow body;

- the closing means are closed and the device is extracted, bringing the material held inside the hollow body by the closing means. Advantageously, the device is inserted into the concrete from the top downwards, so that the closing means open automatically and are thrust upwards by the same material, while during the extraction step, which takes place from the bottom upwards, the closing means are automatically closed by the weight of the fluid material contained in the hollow body, thus allowing the excess concrete which must be removed to be extracted.

The removal device 1 is thus particularly simple and therefore robust and little prone to damage but, at the same time, extremely effective and allows to remove the material quickly, before its solidification, with very simple operations. The opening/closing mechanism then takes advantage of the volume and weight of the same material, without requiring any other type of actuations, in particular to bring the closing means into the closed position, which would make the device more complex, expensive and more prone to breakages.

Advantageously, the first open end 3 of the hollow body can comprise a supporting and attaching portion 9 to be able to fasten means for its movement to the device.

In addition, in order to facilitate the step of inserting the device into the material, the second open end of the hollow body can comprise a flared portion 10 of conical shape in the case of a tubular hollow body, which narrows with respect to the section of the hollow body to act as a pilot for centring inside the element in which it must be inserted. In a first embodiment, the closing means can be combined with the hollow body at an initial end of the conical portion, as shown in figures 1 to 4c, or at a terminal end thereof, as shown in the embodiment of figures 5 to 8c.

The hollow body can also comprise at least one window-shaped side opening 11 to assist the entry of the material into the hollow body during the filling and unloading of the material, once it has been collected, both to eliminate it and to unload it into a special container for subsequent reuse, e.g. for making a subsequent pile.

In addition, in order to facilitate the device to be emptied, means can be provided to allow the collected material to come out through the second open end 4 or through an openable side portion 12 formed in the hollow body. For this purpose, the device can comprise control means for keeping the closing means in the closed position B during the operations of collecting the material and for allowing the closing means, or a portion thereof, e.g. a central portion thereof, to move to the second open position C, once the material has been removed, or for opening the openable side portion.

The control means can comprise, e.g., a cable 13 preferably made of steel, inserted in a special protecting seat 13’ which is combined with the closing elements and which can be operated by means of an automatic or manually-operated lever 14, also removable, fastened to an upper part of the device, as shown in figure 10. Alternatively or in addition, the control means can comprise locking elements 15, e.g. an extractable and/or rotatable pin combined with the closing means or with an openable portion of the closing means of the device, or with the openable side portion 12 of the hollow body, as shown in figures 9a and 9b. Thanks to this configuration, by operating the lever, the closing means, or a part thereof, are pulled into the first open position A to at least partially release the second open end and allow the material to come out so as to empty the device; the lever can be easily removed from the device and re-mounted in case of need; alternatively, the lever can be provided with a hydraulic control or an electric motor - not shown.

Alternatively, a system can be provided, comprising locking elements 15 in the form, e.g., of an opening worm screw combined with the device.

In a different solution, the hollow body can comprise an upper portion and a lower portion having at least one openable side portion 12 that are joined by a hinge 16, so that the openable side portion can be displaced by rotation around such hinge; this displacement can be adjusted manually, or with automatic control, e.g. through locking means 15 in the form of a key which interact with an end portion 4’ of the second open end and which, by rotating through 90°, enable the counteraction to be removed from the openable side portion, thus allowing it to be opened by natural hydraulic thrust.

Alternatively, a screw, or worm screw, system can be provided, which allows to tighten or enlarge the end portion 4’ of the second open end of the hollow body in order to allow the closing means to move into the second open position, resulting in the coming out of the concrete.

The device has been described with reference to the removal of material from foundation piles but it can be used for various applications requiring the removal of liquids, fluids and generally non-solid materials, such as e.g.:

- the emptying of any liquid, fluid/semi-fluid, plastic material from any cavity, excavation or recess; and

- the emptying of piles, diaphragms, so-called jet grouting, concrete foundations and the like, in the field of construction and geotechnics.

Advantageously, the removal device can be mounted on the most common earth-moving machines but also on the machines normally used to make foundation piles.

Suitably mounted on the machines for making piles, with the addition of an upper disc of suitable diameter, which acts as a thrust plate, the device can allow to thrust the cage, to be combined with the upper portion of the pile, into the hole filled with concrete, thus avoiding the use of buckets of excavators which often damage the same cage; by making an element that locks the reinforcement cage around the device, e.g. by means of rubber-coated hydraulic jaws, the driving of the cage into the concrete could be guaranteed without damaging it.

Thus, the idea underlying the present invention starts from the concept of removing the material and in particular the excess concrete, before this begins the setting and hardening process.

Advantageously, such a device and such a solution allow to: avoid all demolition and disposal concrete working currently carried out, which entail a high risk of damage to the reinforcement, as well as the use of extremely expensive systems; avoid exposure of operators to strong vibrations, high noise levels and various hazards of potential injury from crushing by means of large portions of rubble, inhalation of dust, etc.; drastically reduce working times; and - recover and reuse the removed concrete (for high diameter piles, about 0.5 m ³ of material are recovered), which to date is disposed of as demolition debris.

In order to meet contingent and specific needs, a technician of the field can make numerous changes and modifications to the present invention or embodiments shown and described, all thereby comprised in the protection scope of the invention as defined in the following claims.