Note: Descriptions are shown in the official language in which they were submitted.
COM~ ATIOI~l s~D CONCR~TE CASTING Al?P~R~T~S
. . . , _ . . . _ _ _
BACKGROUI~D OF T~ VE~TIO~
The present invention relates generally to the
man~facture of cast concrete structural members and, Inore
particularly, to an improved apparatus for manufacturing
such concrete members in at least two different widths.
To efficiently manufacture cast concrete members
in the form of slabs to be used, for example, as walls,
floors, or roofs in building construction, a batch-type pro-
cess has been employed. In a batch-type process, a long
concrete slab or plan~ is poured and cured, and thereafter
cut into a plurality of shorter length sections. Due to the
relatively long curing time required (approximately 14
hours), this batch-type process is more efficient than cast-
ing individual shorter slabs, because a large number or in-
dividual planks may be produced at substantially the sametime. The length of the slab before cutting into shorter
lengths may be as much as 150 met:ers, with the slab weighing
approximately 230,000 kg. The shorter lengths into which
the slab is cut may range from approximately 2.4 meters long
for a wall span, to 15.2 meters ]ong for a roof span.
It is desirable to be able to use the same appar-
atus to manufacture such slabs in dlfferent widths such
that, as the lengths of the completed slabs are varied, the
overall weight may be kept within tlle capacity of the asso-
ciated lifting crane. For example, 2.4 meter wide slabs ~aybe manufactured for shorter lengths, and 1.2 meter wide
slabs for longer lengths. A previously employed approach to
this problem has been to cast all slabs in single widths,
and then saw longitudinally, with separate casting beds be-
ing used for different widths. While this accomplishes thedesired final result, it has the disadvantages of duplica-
tive apparatus, increased usage of expensive diamond toothed
saw blades, and requires additional costly labor time.
7.~3Z~
By the present invention there is provided an
improved apparatus for manufacturing elongated concrete
structural members in at least two different widths. Appar-
atus embodying the present invention is particularly adapted
for use in making concrete structural members employing
either a fixed bed apparatus or a moving bed apparatus.
Further, there is provided a highly flexible and cost effi-
cient combination concrete bed casting apparatus which enables
a single relatively wider slab section to be produced where
the section is to be cut into relatively shorter lenghts and
transported by the associated lifting crane or two relatively
narrow slab sections to be produced where longer finished
lengths are required but which would otherwise exceed the
lifting capacity of the available crane if made in full width
sections .
The present invention resides in a combination bed
casting apparatus for casting either a single elongated concrete
structural member in a single elongated casting bed section
or for simultaneously casting two elongated concrete structural
members in side-by-side parallel elongated casting bed
sections. The combination bed apparatus has a longitudinally
extending bottom wall form and oppositely disposed side wall
forms, the bottom wall form being divided longitudinally into
two sections for supporting the structural member(s) to be
cast. The two sections are disposed in abutting relationship
to form with the side wall forms the single casting bed
section. An elongated intermediate wall form is positionable
between the two supporting sections and generally parallel
to the side wall forms to form with each supporting section
cbr/~s
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and an associa-ted side wall form the side-by-side casting
bed sections. At least of the supporting sections and its
associated side ~all form is moveable transversely to the
longitudinal axis of the casting apparatus. In the oresent -
invention the intermediate form is pivotally supported by a
lifting mechanism in a first position below ,he moveable
section when the two supporting sections are disposed in
abutting relationship for forming the single casting bed
section and in a second above and between the supporting
sections when the one of the two supporting sections ana its
associated side wall forms have been moved transversely to
form the side-by-side casting bed sections.
In a specific embodiment of the invention, the
intermediate support may be connected to a transverse shift
mechanism supported to the moveable supporting section for
effecting movement of the intermediate support transversely
of the longitudinal axis of the casting apparatus together
with transverse movement of the moveable support section.
More specifically, the shifter mechanism may include
a lost motion linkage which causes the shifter mechanism to
be engaged for travel with the moveable section only during
a portion of the travel of the moveable section during trans-
verse movement thereof.
In accordance with a specific embodiment of the
invention, a plurality of spaced transverse tracks may be
disposed below the casting bed perpendicular to the longi-
tudinal dimension of the bed. To support the bed sections
during relative transverse movement, a plurality of wheels
may be rotationally mounted to the undersides of the casting
`f ~é - 3 -
cbr/~s
,
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bed sections in rolling engagement with the transverse tracks.
In accordance with still another specific embodiment
of the invention, an elongated actuator element extending
along substantially the entire length of the casting bed,
S preferably along the center thereof, is provided for trans-
versely moving the casting bed sections. The element is
mounted for longitudinal, but not lateral, movement. A
plurality of swing arms extend laterally and symmetrically
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cbr/'~S
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from the actuator element to koth of the cas-ting bed sections. A hydraulic
actuating arm is provided for longitudinally moving the actuator ele~en-t to
produce resultant transverse vement of the castina bed sections.
To raise and lower -the intermediate form, a plurality of vertical swing
arms are pivotally attached ket~een the intermediate form and a plurality of
anchor ~mbers such that longitudal movement of the intermediate fo m produces
a resultant vertical movement of the longitudinal form.
In yet another e~bodiment of the invention, only one of the casting ~ed
sections is movable, while the other is fixed. However, the sections are still
movable transversely relative to each other.
BRIEF DESCRIPTION OF THE DR~WI~GS
. .
~nile the novel features of the invention are set forth with particularity
in the appended claims, the invention, both as to organization and oontent,
will be better understood and appreciated, along with other objects and
features thereof, fro~ ~he following detailed description -taken in conjunction
with the drawings, in which:
FIG. 1 is a top plan view of a fixed bed a~paratus according to a first
` embodlm n-t of the invention showing the cast mg oE a pair of relatively
narrower slabs;
FIG. 2 is an enlarged vertical section -taken along line 2-2 of FIG. l;
FIG. 3 is a further enlarged sectional view showing the riaht side fonm
of FIG. 2 in -the upright position;
FIG. 4 is a view of the right side form of FIGS. 2 and 3 in the lowered
~osition for sawing and removal of the cast slab;
FIG. 5 (on the sa~e sheet as Figure 1) is a fragmen-tary perspective view
showing the swing arm mechani ms for raising and lowering the intermediate
form and for transversely moving the casting ~ed secti~ns in the apparatus of
FIGS. 1 and 2;
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FIG. 6 is a greatly enlarged sectional view showing details of the inter-
face between the interrr,ediate form and the bottoms of the bed sections in the
emtodlment of FIG. 2;
FIG. 7 is a view similar to FIG. 6 where the intermediate form has been
remo,ved and the casting ked sections movedclosely adjacent one ~nother to
produce a single relatively wider slab;
FIG. 8 is a vertical section similar to FIG. 2 showing a second embodlmant
of the invention e~,ploying hydraulic cylinders for transverse move~ent of
and separation of the castina bed sections;
FIG. 9 (on the same sheet as Figure 6) is a fragmentary section taken
generally along line 9-9 of FIG. 8 showing vertical movement of the
inte~rediate form;
FIG. lO(on the same sheet as Figure 6~ is a perspective view of the
vertical swing arm of the embodiment of FIGS. 8 and 9;
FIG. 11 is a vertical section similar to FIG. 2 showing a third em~odiment
of the invention a~plied to a moving bed apparatus;
FIG. 12 is a highly schematic vextical section simiL~r to FIG. 2 showing
a fourth em~odiment of the invention wherein only one of the castin~ bed
sections moves transversely~ with the other casting bed section beinq fixed;
FIG, 13 is a view of the FIG. 12 embodlment showing the config~ration
when the left-hand casting bed section and the intermediate form assembly
have rnoved away from the stationary right-hand castin,a bed section;
- FIGo 14 is a view of the FIG. 12 entodin~nt showing the configuration
when the intermediate forrn assenbly is lowered and the side form assemblies
are pivoted away, ready for transverse sawing and removal of the cast concrete
members;
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FIG. 15 is a view similar to FIG. 12 showing the
YIG. 12 embodiment in a configuration for casting a single,
~ull-width concrete slab;
FIG. 16 is an enlarged sectional view showing the
configuration of FIG. 12 in greater detail;
FIG. 17 is a further enlarged sectional view show-
ing the intermediate form assembly of FIG. 18 in greater
detail;
FIG. 18 is an enlarged sectional view showing tlle
configuration of FIG. 15 in greater detail;
FIG. 19 is a side elevational view taken along
line 19-19 of FIG. 18 showing details of the arrangement for
effecting vertical movement of the intermediate form
assembly;
FIG. 20 is a plan view taken along line 20-20 of
FIG. 19;
FIG~ 21 is a view taken generally along line 21-21
of FIG. 20 showing the manner in which lateral movement of
the intermediate form assembly away from the Eixed casting
bed section is effected; and
FIG. 22 is a side elevation taken along line 22-22
of FIG. 16 showing details of the left side form assembIy in
the embodiment of FIGS. 12-21.
DETAILED DESCRIPTION OF THE PREFERRED EMBODI~ ITS
Referring first to FIGS. 1 and 2, there is illus-
trated a stationary bed apparatus of the typewell known in
the art. The apparatus includes an enlongated horizontal
casting bed 22 having a lon~itudinally extending bottom wall
24 and longitudinally extending left and right side form
walls 26 and 28.
A trackway comprises longitudinally extending
rails 30 and 32 which support the various units (not shown)
such as casting and cutting units which travel the length
of the casting bed 22.
~7~
7--
In accordance with the present invention, the
castin~ bed 22 is divided longitudinally along the bottom
wall 24 into sections moveable transversely relative to one
another. In the illustrated embodiments, there are two
such sections designated 34 and 36, and the bottom wall 24
is divided at 38 in the center thereof to form separate bot-
tom wall sections 40 and 42. An elonyated, remova'~le inter-
mediate form 44 is provided which is positionable between
the two casting bed sections 34 and 36, generally parallel
to the side form walls 26 and 28.
In the configuration illustrated in FIGS. l and 2
where the intermediate form 44 is in place-, separate con-
crete members 46 and 48 may be manufactured in the bed sec-
tions 3~ and 36. When the intermediate form 44 is removed
in the manner hereinafter described in greater detail, and
the casting bed sections 34 and 36 moved closely adjacent
one another so that the bottom walls 40 and 42 thereof join
to form a substantially continuous bottom wall, a sinyle
concrete member extending from one side to form wall 26 to
the other side form wall 23 may be manufactured. The rein~
forced slab or plank produced by this process may be formed
by means of a plurality of operations utilizing a separatë
soffit laying unit and a main casting machine.
To accommodate relative transverse movement of
the casting bed sections 34 and 36, a plurality of spaced
transverse tracks 50 are disposed below the casting bed 22
perpendicular t~ the longitudinal dimension of the bed 22.
The transverse rails 50 may be spaced, Eor example, at in-
tervals of six meters, along the entire length of the cast-
ing bed 22. The length of the casting bed 22 is in the
order of 150 meters. A plurality of grooved ~heels 52 are
rotationally mounted to the undersides of the casting bed
sections 34 and 36 in rolling engagement witll the transverse
tracks 50 so as to support the bed sections 34 and 36 during
relative transverse movement thereof. More particularly,
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~27~32~
each of the wheels 52 is mountecl by suitable bearing means
within a wheel housing 54 secured ycnerally to tlle unc~er-
sidcs of the sections 34 and 36. As shown, the axes o~ the
grooved wheels 52 are parallel to the longitudinal dimension
of the casting bed 22.
Since the apparatus 20 of FIGS. 1 and 2 is a
fixed bed apparatus, the longitudinal rails 30 and 32 and
the spaced transverse rails 50 are firmly fixed to the
ground via a concrete base 55.
Due to the relatively wide six meter spacing be-
tween the transverse rails 50 and the extreme weight o~ the
cast concrete members, it will be apparent that a substan-
tial support structure is required to avoid objectionable
sagging between the support points comprising the transverse
rails 50 and the ~heels 52 with associated housings 54. To
this end, Z beams 56 extend along the sides of the casting
bed sections 34 and 36 below the side edges of the bottom
wall sections 40 and 42. While the ~ beams 56 run contin- ;
uously along the entire length of the casting bed 22, they
may comprise individual sections approximately twelve meters
long suitably joined together. Extending transversely be-
tween the ~ beams 56 are a plurality of I beams 58 spaced
appro~imately 0.75 meters apart along the length of the
casting bed 22. Finally, to support the bottom wall
sections 40 and 42, beams such as C beams 60 bridge across
the I beams 58.
Referring now in addition to FIG. 2, to FIGS. 3
and 4, the ri~ht side form wall 28 will be described. It
will be apparent that the left side form wall 26 is a mir-
ror image, and identical reference numerals are applied
thereto. ~loveable side form walls are well known in the
prior art and the illustrated embodiment is merely intended
to provide one suitable e~ample. It will be apparent there-
fore that the precise details of the side form walls 26 and
28 are not critical to the present invention.
~Z~ 6
g
The right side form wall 28 has a side form actu-
ator 64 in the form of a plate of generally triangular con-
figuration having a pivot point 6~ mounted to the Z bar 56
disposed generally below the r,ight side form wall 28 by
means of a suitable bracket 68. The right side form wall 28
is suitably attached such as ~y bolting to the upper portion
of the actuator 64. A sliding cam member 70 is attached via
a screw type adjustment mechanism 72 to the tail portion 74
of the actuator 64.
In order to force the actuator 64 and right side
form wall 28 upright into the position of FIGS. 1, 2 and 3,
a cam actuator 76 extends along the length of the casting
bed 22 along the side thereof. The cam actuator 76 has an
outer surface 78 of varying width, as best seen in FIG. 1.
The cam actuator 76 is movable longitudinally relative to
the casting bed 22, and is pulled and pushed by means of
hydraulic actua-ting cylinders (not shown) located the ends
thereof.
For lowering the side form wall 28, to the posi-
tion illustrated in FIG. ~, the cam actuator 76 is pulled toa position where o~e of the low portions of -the outer sur-
face 28 engages the sliding cam member 70, allowing the ac-
tuator 64 and right side form wall 28 to fall away. In most
cases the side form wall 28 and actuator 64 will not fall
actuator ~ will not fall away on their own accord, but
will do so after being struck.
Still referring to FIGS. 3 and 4, side wall exten-
sion members 8~ and 82 are shown which may optionally be
added to the right side form wall 28 when it is desired to
cast thicker slabs. The extension members 80 and 82,are al-
so shown in phantom lines in FIG. 2. Although not illus-
trated it will be apparent that where it is desired to rnanu-
facture a pair oE relatively narrower thicker slabs, an ex-
tension rnember (not shown) will also be required on the
intermediate forrn 44.
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.
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Referring now to FIG~ 5, there are shown details
o the mechanism according to the invention for raising and
lowering the intermediate form 44 and for transversely mov-
ing the casting bed sections 34 and 3~ of the first embodi-
ment of the apparatus 20 of FIGSo 1 and 2. Considering firstthe intermediate form 44, the intermediate ~orm 44 is
mounted for vertical movement by means of a plurality of
vertical swiny arms, one of which swiny arms is designated
84 in FIG. 5. The upper end of the vertical swin~3 ar;n ~4 is
pivotally attached at 86 to the intermediate form 44, and
the lower end of the swing arm 84 is pivotally attached at
88 and one of a plurality of anchor members 90. In the em~
bodiment of the apparatus 20, which is a fixed bed appar-
atus, the anchor members 90 are firmly fixed relative to the
ground. There is additionally provided a means for longi-
tudinally moving the intennediate form 44, which means may
comprise an hydraulic cylinder 92 located at either or both
ends of the intermediate form 44. The hydraulically actu-
ated cylinder is pivotally attached at94 to the intermediate
form 44, and at 96 to a suitable Eixed support (not shown).
It will be apparent thal: longitudinal movement of
the form 44 effected by extension and retraction of the
hydraulic cylinder 92 produces a resultant vertical move-
ment of the intermediate form 44 as the vertical swing arm
~4 pivots about the point 88. As shown in FIG. 5, the in-
termediate form ~4 is raised to nearly its fully upright
position wherein the botto,o of the form 44 is above the bot
tom wall 24 (FIG. 2) of the casting bed 22. In the fully
lowered position which occurs when the intermediate form 44
is moved to the ri(3ht and downward as shown in FIG. 5, the
top of the intermediate form 44 is below the casting bed
bottom wall 24.
Still referring to FIG. 5, the means for trans-
versely moving the castiny bed sections 34 and 3~ of the
first embodiment of the apparatus 20 includes an elon~3ated
~2~
actuator element 98 in the forln o a len~th of steel tub-
ing. The actuator element 98 extends along substantially
the entire length of the casting bed 22, and is mounted or
longitudinal, but not lateral movement. In order to longi-
tudinally Inove the actuator element 98, a hydraulically ac-
tuated cylinder 100 is ;nounted at one end thereof. Prefer-
ably, the elongated actuator element 98 extends alon~ sub-
stantially the center of the casting bed 22, just above the
spaced transverse rails 50. In order to avoid interference
between the actuator element 98 and the vertical swing arm
anchor member 90, the anchor members 90 have passageways 102
through which the actuator element 98 freely passes. If
desired, the passageways 102 may include bearings or bush-
ings for securing the actuator element 98 against lateral
movement.
To convert longitudinal movement of the elon-
gated actuator element 98 to resultant transverse relative
movement of the casting bed sections 34 and 3G, swing arms
104 extend between the actuator element 98 and the casting
bed sections 3~ and 36. The swing arms 104 are each pivot-
ally attached at one end 106 to the actuator element 98, and
at their other ends 108 to the casting bed sections 34 and
36. In the illustrated embodil~lents, the pivotal attach-
ments 108 to the casting bed sections 34 and 36 are conven-
iently made to suitable tabs attached directly to the wheel
housings 54.
In the illustrated arrangement with the actuator
element 98 extending along substantially the center of the
casting bed 22 and the swing arms 104 extending laterally
and symmetrically from the actuator element 98 to the cast-
ing bed sections 34 and 36, it will be apparent that the
lateral forces acting on the actuator element 98 are sub-
stantially in balance so there is minimal tendency towards
lateral movement thereof. From FIG. 5, it will be apparent
that longitudinal movement of the actuator element caused by
7~12~i
-12--
operation of the hydraulic cylinder 100 produces a resultant
transverse movement of the casting bed sections 34 and 36.
FIGS~ 6 and 7 show the region of inter~ace be-
tween the bottom wall sections 40 and 42 with the intermedi-
ate form 44 respectively in place and removed. FIGS 6 and 7,
being enlarged views, also illustrate welds 110 which join
the bottom wall sections 42 and 44 to the Z beams 56.
Referring in particular to FIG. 6, the inter~
mediate form 44 is positioned between the casting bed sec-
tions 34 and 36, and more particularly between confronting
edges 112 and 114 of the bottom wall sections 40 and 42.
Thus individual concrete members 46 and 48 may be manufac-
tured in the two casting bed sections 34 and 36.
In FIG. 7, the intermediate form 44 is effec-
tively removed from its position between the casting bed
sections 34 and 36 by being lowered below the bottom wall
sections 40 and 42. In this view, the casting bed sections
34 and 36 are moved closely adjacent one another so the the
confronting edges 112 and 114 of the bottom wall sections
~0 and 42 cooperate to form an effective seal against the
leakage of uncured concrete material. Thus, in this con-
figuration a single concrete member 116 extending from one
of the side form walls 26 and 28 of FIG. 2 to the other may
be manufactured.
In FIGS. 6 and 7, it will be observed that the
bottom wall sections 40 and 42 are curved upward in the
vicinity of their confronting edges 112 and 114. When a
pair of slabs 46 and 48 are produced as in FIG. 6, this cur-
vature produces curved bottom edges at 118 on the slabs 46
and 48. Where a single slab 116 is produced as in FIG. 7,
this curvature produces a channel 120 which serves an ap-
pearance function upon ultimate installation of the slabs by
making it difficult to distinguish an interface between two
narrower slabs and the midpoint of a wider slab. This is
advantageous in those instances where the total width of the
13-
building structure concerned is e(lual to the combined wiclths
of an odd number of relatively narrower concrete structurai
members and relatively shorter lengths are required. In
such a situation, full widtil structural melnbers are within
the lifting capacity of the crane, but at least one half
width section is required to fit the dimensions of the
building structure.
The operation of the first embodiment 20 which llaS
been described with reference to FIGS. 1 through 7 will now
be summarized. It will be assumed that relatively narro~er
structural members are being produced. Following the cast-
ing of one batch, the cured slabs 46 and 48 are in thei.
position as shown in FIGS. 1, 2 and 6. The cam actuators 76
at the sides of the casting bed 22 are pulled longitudinally
to release the actuators 64 and the left and right side form
walls 26 and 28 the side form walls 26 and 28 are allowed to
fall away by pivoting about the points 66 to assume the
positon shown in FIG. 4. As previously mentioned, a blow
such as kick may be required to release the side form walls
26 and 28.
At this point, the hydraulic cylinder 100 at the
end of`the elongated actuator element 98 is operated to
separate the casting bed sections 34 and 36 through opera-
tion of the swing arms 104. The intermediate form 44 is
then lowered below the level of the bottom wall sections ~0
and 42 by allowing the hydraulic cylinder 92 to extend. At
this point, the slabs 46 and 48 are sitting freely on top
- of the bottom walls 40 and 42, and may be transversely
- sawed into sections of desired lengths. It will be appreci-
ated that the lowe~ing of the intermediate form 44 and the
pivoting away of the side form members 26 and 2~ provides
clearance for the circular saw blade employed.
Following the sawing operation, the individual
slab lengths are lifted by crane out of the casting bed sec-
,
.;. ' : :
.
:
:.
tions 34 and 3~ and transported to a storage area or to a
vehicle.
To begin the next batch, the side forms 26 and 28
are raised by operating the cam actuators 76, and the inter-
mediate form 44 is raised by operating the hydraulic cylin-
der 92. The intermediate form 44 is properly positioned be-
tween the casting bed sections 34 and 36, and the castiny
bed sections 34 and 36 are moved together to seal against
the intermediate form 44 as shown in FIGS. 2 and 6. ~t this
point, the bed sections 34 and 36 are cleaned and oiled in
preparation for receiving a new batch of concrete.
It will be appreciated that in the event full
width slabs are being manufactured, the intermediate form
raising and bed separating mechanisms shown particularly in
FIG. 5 are not used, and the operation proceeds simply as a
single bed appparatus.
Re~erring now to FIG. 8, there is shown an alter-
native embodiment of the invention embodied in an apparatus
122. T~le apparatus 122 is a modification to the previously-
described apparatus 20, and a number of elements which are
unchan~ed are desic3nated by identical reference nuMerals.
The apparatus 122 o FIG. 8 is also a fixed bed apparatus
and accordingly includes the longitudinal rails 30 and 32
for movement of the various items of equipment along the
casting bed 22.
The primary diference in the FIG. 8 embodiment
is in the means for transversely moving the casting bed sec-
- tions 34 and 3~ relative to eacil other. The apparatus 122
o~ FIG. ~ still has the spaced transverse rails 50 and the
grooved wheels 52 ~or supporting the bed sections 34 and 36
and accommodatinc3 transverse movement thereof. ~lowever, in~
stead of the elongated actuator element 98 and the swinc3
arms 104, laterally extending hydraulically acutating cylin-
ders 124 are elnployed. One end of each of the cylinders 124
is connècted to the casting bed sections 34 and 36, preer-
' ~15-
ably to the wheel housings 54 at attachment points 12G. The
other ends of the hydraulic cylinders 124 are attached at
points 128 to gusset li~e supports 130 which, for the fixed
bed apparatus 122, are fixed relative to the ground. ~ddi
tional gusset like members 132 serve as stops to limit the
transverse movement of tlle beds 34 and 36 by contacting the
wheel housings 54.
Referring now to FIGS. 9 and 10, there is illus-
trated the form of the vertical swing arms used to raise and
lower the intermediate form 44 in the apparatus of FIG. 8,
which form 44 is otllerwise unchanged. In FIGS. 9 and 10,
the anchor members 90, and specifically the passageways 102
thereof, embodiment (as shown in Fig. 5) are not required.
The lower ends of the modified swing arms 132 are pivotally
attached at 134 to members 136 wh-ich abut the spaced trans
verse rails 50. Since the force on the pivot points 134 is
all in one direction, the use of the abutting members 136
provide a convenient way to effectively anchor the lower
ends of the swing arms 132. The upper ends of the modified
swing arms 132 are connected as before to the intermediate
form 44. In FIGS. 9 and 10 it wi:Ll also be observed that
the modified vertical swing arm 1:32 inclu~es turnb~ckle
members 138 cooperating with threads 140 to allow length
adjustment of the vertical swing arms 132.
It should be noted that FIG. 9 provides an illus-
tration of two positions of the intermediate form 44 with
reference to the bottom wall 24 of the casting bed 22.
Shown in full lines is the lowered position of the inter-
mediate form 44 which is the position where the interme-
diate form 44 is effectively removed. Shown in phantom
lines is the full upright position used for pulling the in-
termediate form 44 away from the slabs 46 and 48. The posi-
tion of the intermediate form 44 for casting the concrete
members is not illustrated in FIG. 9, but is a position
slightly below the upper position shown in phantom lines,
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which occurs wJlen the transition 142 coincides with the hot-
tom wall 24.
Referring next to FIG. 11, there is sl~own another
embodiment of the invention embodied in an apparatus 144,
which is a moving bed system. The entire bed 146 rolls
longitudinally on grooved wheels 148 ridiny a trac~ compris-
ing rails 150 and 152. Thus, instead of resting on the
ground, the transverse rails 146 (corresponding to the pre-
viously-described transverse ralls 50~ are supported by the
wheels 148. In the moving bed system, the various items of
equipment generally remain stationary while the bed 146
rolls longitudinally. To support this equipment, I beam
side members 156 are provided, with rails 15~ at- the tops
thereof. Variable speed reversible hydraulic snotors 160
having rubber drive hydraulic motors 160 havingrubber drive
wheels 162 frictionally engaging the sides of the I beams
156 are provided to move the bed 146.
The moving ~ed 146 of the apparatus 144 of FIG.
11 is otherwise essentially the same as the fixed bed 22 of
the apparatus 122 of the FIG. 3 embodiment. It should be
noted that the spaced transverse rails 154 are no lon-3er
fi~ed to the ground, but rather are attached to the housing
of the wheels 148. The lower ends of the vertical swing
arms 132 are attached to suitable luys (not shown) on the
rails 154. Additionally, the hydraulic cylinder 92 ~FIG.
5) for operating the intermediate form 44 is not fixed to a
statiohary support, but rather is fixed relative to the
framework of the moving bed 146.
Referring now to FIGS. 12, 13, 14 and 15~ a com-
bination bed concrete casting apparatus 200 constructed in
accordance with a fourth embodiment of the invention is il-
lustrated in highly schematic form. r~he casting bed 200 is
divided longitudinally in two sections 202 and 204. While
the sections 202 and 204 are movable transversely relative
to one anothèr as in the previous embodiments, the combina
-17-
tion bcd 200 differs from the previously-describcd embodi-
ments in that only one of the sections 202 and 204 is mov-
able relative to the ground, and the other remains fixed
relative to the grouncl. In the illustrated embodiments the
left casting bed section 202 is movable, ~lhile the right
hand casting bed section 204 is fixed. This particular ar-
rangement is in many respects simpler to construct then thc
previously-described embodiments in that it minimizes the
need for heavy moving elernents.
In FIG. 12 may be seen a pair of separate concrete
members 206 and 208 (phantom lines) molded in the apparatus
200. The concrete members 206 and 208 are supported on re-
spective pallets 210 and 212 comprising the sections 202 and
204, are separated by an intermediate form assembly 214, and
are bounded by left and right side form members 216 and 218,
respectively.
The overall sequence of operations involved in
manufacturing two one-half width ~for example each 1.2
meters wide) concrete members 202 and 204 will now be de-
scribed with particular reference to FIGS. 12, 13 and 14.
FIG. 12 illustrates the situation when the inter-
mediate form assembly 214 and the left and ri~3ht side form
assemblies 216 and 218 are in position for casting and
curing.
As illustrated schematically in FIG. 13 following
the curing of the concrete comprising the members 206 and
208 in the same manner as previously described, the movable
casting bed section 202 moves transversely to the left r away
from the fixed casting bed section 204. The arrangement is
such that the movable section 202 initially moves away from
both the intermediate form 202 and the fi~ed section 204,
while the intermediate form assembly 214 remains slightly
- adhered to the concrete member 208. At a certain point in
its transverse movement, an element of the movable section
202 engages the intermediate form 202, pulling the inter-
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mediate for~ assernbly 214 laterally away ~rom the fixed sec-
tion 204, and away ~rom tlle concrete member 208. (This L~ar-
ticular action is described in ~reater detail below with
reference to FIG. 21).
Next, as may be seen from-FIG. 14, the intermedi-
ate form assembly 214 is lowered below the pallets 210 and
212 comprising the casting bed sections 202, and the left
and right side ~orms 216 and 218 are pivoted away. In this
this confi~uration, the concrete slab members 206 and 208
may be sawed into sections of any desired len~th as ~revi-
ously described, and thereafter lifted out of the respective
casting bed sections 202 and 204 by means of a crane.
FIG. 15 illustrates the configuration for casting
a single full width (for example 2.4 meters ~ide) concrete
member 220. In the FIG. 15 configuration, the interme(liate
form assembly 214 remains below the pallets 210 and 212 com-
prising the casting bed sections 202 and 204, and the mov-
able casting bed section 202 is closely adjacent the fixed
casting bed section 204, forming in effect a single wide
casting bed.
Upon the completion of a casting and curiny opera-
tion to produce the sin~le full width concrete member 220,
the side form members 216 and 218 are pivoted away, and the
concrete member 220 is sawed into individual slabs of de-
sired length which are lifted o~t of the casting bed 200, in
the manner previously described.
FIG. 16, which may be compared to FIG. 12, illus~
- trates various constructional details of the apparatus 200,
while FIG. 17 illustrates further details of the intermedi- ;
ate form assembly. The intermediate form assembly 214 con-
prises left and right lower sections 222 and 224, left and
right middle sections 226 and 228, and left and right upper
sections 230 and 232 joined by a support element 23~. The
lower sections 222 and 224 are permanent parts of the inter-
mediate form assembly 214, while the sections 226, 228, 230
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and 232 are optionally installed wllen it is desired to cast
concrete slabs of greater thic~ness than is possible with
the sections 230 and 232 alone.
Shown in phantom lines in FIG. 16 is the positior
of the intermediate form assembly 214' when lowered below
the pallets 210 and 212 either for the purpose of p~rmitting
sawing of the concrete members 206 and 208 as in FIG. 14, or
for the purpose of permitting the casting of a single full-
width ~2.4 meter) concrete member. In the lowered position
shown in phantom lines in FIG. 16, the intermediate form
assembly top sections 230 and 232l as well as the support
element 234, are removed~ and the middle sections 226 and
228 are pivoted about respective pivot points 23h and 238
after removing bolts 240 and 242 (FIG. 17).
As may be best seen in FIG. 17, in the upper posi-
tion of the intermediate form assembly 21~, slight ledges at
244 and 246 on the intermediate form assembly 214 enga~e
lips 24R and 250 of the respective movable and ixed pallets
210 and 212, and are supported tilereby. Lateral registra-
kion of the assembly is effected by abutlnent of the sides of
the lips 248 and 250 against downward projections 252 and
25~ cornprising "L" members extending from adjacent ledges -
244 and 246 and attaclled by means of bolts 256 and 258 to
the intermediate form assembly 214.
In FIG. 16, the left and right side form assem-
blies 216 and 218 are substantially identical to tllose co[n-
prising the left and right side form walls 26 and 28 de-
scribed above with particular reference to FIGS. 3 and 4.
As in the previous embodiments, each of the side form assem-
blies 216 and 218 comprises a triangular actuator 264 pivot-
ing about a point 266 suitably affixed to the respective
- pallets 210 and 212. A sliding cam member 270 is attached
via screw-type adjustment mechanisms 272 to tail portions
274 of the actuators 264.
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In order to force the actuators 26-1 and the side
form assemblies 212 upright into the position illustrated in
FIG. 16, cam actuators 27G extend along tlle length of the
combination bed assembly 200, as may be best seen in FIG.
S 22, described hereinafter. The cam actuator 27G has an
outer surface of varyiny width. As a cam actuator 276 is
moved longitudinally, the let and right side form members
212 and 214 are raised and lowered in the manner previously
described.
Also as previously described, side ~all extension
members 280 and 282 may optionally be installed when it is
desired to cast thic~er concrete members. It will be appre-
ciated that the extension members 280 correspond to the mid-
dle sections 226 and 228 of the intermediate form assembly
21~, and the top extension member 282 correspond to the top
sections 230 and 232 of the intermediate form assembly 214.
As mentioned above, a distinc~uishinc3 characteris-
tic of the embodiment described herein beginnin~ with reer-
ence to FIG. 12 is that one of the two casting bed sections
is immovably fixed to the ground. As may be seen in FIG.
16, in the particular arrangemellt illustrated, the casting
bed section 204 is fixed to the ground 284 by means of em-
bedded anchors 286, I beam supports 288 and support struc-
ture 290 generally supporting the pallet 212.
On the other hand, the casting bed section 202 i5
trans~rersely (laterally) rnovable, with the lateral movement
generally being effected by means of an hydraulic cylinder
292. Hydraulic cylinder 292 has an extending piston rod
294, the end 296 of which is affixed to a sliding assembly
generally designated 298. The sliding assembly 298 com-
prises the pallet 210 of the movable section 202, support
structure 300, including box-section beams 302, a tie member
304 extending between the box-section beams 302, and slide
plates 306. This assembly 298, more particularly the slide
plates 306, is slidably supported on the outer surface of a
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box-section beam 308 alongside the body of the hydraulic
cylinder 292. The beam 30a is fixed in position by means of
supports 310 attached to embedded anchors 312. The opposite
end 314 of the hydraulic cylinder 292 is anchored to an at-
tachment assembly 316 on the end of the sleeve 308, tllereby
ensuring that the hody of the cylinder 292 does not move.
Preferably, to ease assembly tolerance require-
ments, the connection of the cylinder end 31~ to tlle attach-
ment assembly 316, as well as the attachment of the piston
rod end 296 to the sliding assembly, each permit pivotal
movement about a vertical axis. It is additionally prefer-
able that a mechanical stop (not sllown) be provided to pre-
vent further retraction of the piston rod 294 into the body
of the cylinder 292 beyond tlle position which pr~duces tlle
fully-open configuration of FIGS. 13 and 1~.
FIG. 18 is a detailed view similar to that of FIG.
16, but shows the piston rod 294 of the hydraulic cylinder
292 fully extended, with the two casting bed pallets 210 and
212 in abutment at their respective lips 2~$ and 250, thus
forming a single, wide (2.4 meter3 casting bed. In this
configuration, the intermediate form assembly 21~ is in its
lowered position, as was seen only in phantom lines in ~IG.
16. In the lowered position of the intermediate form assem-
bly 214, the top sections 230 and 232, visible in FIG. 17,
have been removed, as well as the support element 234. The
middle sections 236 and 238 are manually pivoted inwardly in
order to fit within the available space.
In the con~iguration of FI~. 18, for sawing and
removing of the cast concrete member 216 it is only neces-
sary to pivot the side form members 216 and 218, in the man-
ner previously described and as is shown in phantom lines in
FIG. 18.
With reference to FIGS. 19, 20 and 21, the manner
in which both vertical and transverse movement of the inter-
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mediate form assembly 214 is accomplished will now be
described.
Similar to the previously described embodiments/
vertical Inovement of the intermediate form assembly 214 is
effected by means of hyclraulically actuated swinc3 arm assem-
blies comprisiny swing arms 318 and 320, and a re~resenta~
tive hydraulic actuating cylinder 322. The intermediate
form assembly 214 extends for approximately 180 meters, and
may comprise individual sections of any suitable length.
Swing arm assemblies and l-ydraulic actuatiny cylinders such
as the swing arm assemblies 318 and 320 and the hydraulic
actuating cylinder 322 are suitably spaced alon~ the length
of the intermediate form assembly 21~. The swing arms as
pivctally attaciled as at 324 and 326 to mountiny plates 3~8
and 330 securely affixed to the ground 28~1 by means of par-
tially embedded bolts 332. The hydraulic cylinders such as
the cylinder 322 are also pivotally attached as at 33~1 to
selected ones of the mounting plates, for example the mount-
ing plate 330.
Not all of the swiny arms need have hydraulic ac- -
tuating cylinders directly attached thereto. ~s may be seen
from FIG. 19, the representative swing arrn 31% is directly
hydraulically actuated, while the representative swing arm
320 passively pivots only. By way of example, in one par-
ticular embodiment only one out oE every fifteen swing arm
assemblies is directly power actuated. More particularly,
120 swing arm assemblies are spaced 1.5 meters apart along
an intermediate form assembly 21-1 which is 180 meters in
length. ~lost of the swing arms are passive such as the rep- ;
resentative swing arm 320, while every fifteenth swiny arm
is directly actuated, such as the representative swiny arm
318. Accordingly, there are eight directly actuated swing
arms such as the swing arm 318, with 22.5 meter spaciny.
To actually raise and lower the intermecliate form
214, the swing arms such as 318 and 320 are pivotally at-
.
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tached at their upper ends 336 and 338 to the intermediate
form 214. ~lore particularly, "C" section members 340 ~see
also FIG~ 17) extend horizontally between the intermediate
form lower sections 222 and 224, being secured at eitiler end
to respective end brac~ets 342 and 344~ Slotted pivot lin~-s
346 and 348 are welded to the horizontal "C" section menbers
340, witll the slots receiviny pivot pins 350 and 352. ~he
purpose of the slots in the pivot lin};s 346 and 348 is to
accommodate thermal expansion along the len~th of the inter-
mediate form 214. Preferably, a set of pivot lin};s (not
shown) at the lon~3itudinal midpo.int of the intermediate form
214 has round apertures, thereby establishiny a reference
point from which thermal expansion and contraction occurs
longitudinally in both directions.
Lateral or transverse movement of the center form
assembly 214 is effected by means of transverse shifter arms
354 which, as may be seen from FIC;S. 20 and 21, are fixed to
each of the swing arm assemblies. ~s may best be seen in
FIG. 20, the pivotal attachments 324 and 326 for the repre-
sentative swing arms 318 and 320, as well as tlle pivotal at-
tacllment 334 for the representative hydraulic cylinder 322,
permit transverse or lateral movement of all the swing arm
assemblies and the intermediate form 214. A particular
feature of the casting bed embodiment 200 described begin-
ning with reference to FIG. 12 is that lateral movement of
the movable section 202 away from the fixed section 204
under the urging of the hydraulic cylinders 292 (FIGS. 16
and 18) automatically produces lateral movement of the in-
termediate form assembly 214 by means of the transverse
shifter arms 354 and lost moti.on lin~a~es 356 carried by the
movable section 202.
Referring in particular to FIG. 21, a representa-
tive lost motion linkage 356 includes a downwardly extending
element 358 and a braciny member 360 carried by the support
structure 300 of the movable casting bed section 202. In
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FIG. 21, tlle confiyuration when the hydraulic cylinder pis--
ton rod 294 (FIGo 1~) is fully extended anc] the lips 24~ an(l
250 of the pallets 210 and 212 are in abutment is sho~1n in
solid lines, while the corliguration when the hydraulic cy-
linder piston rod 294 is retracted and the movab1e castiny
bed section 202 is moved transversely away from the fixed
bed section 204 is shown in phantom lines, with identical
elements denoted by primed reference numerals.
More particularly, the lower portion of the ele-
ment 358 is apertured at 3G2, and the transverse shifter arm
354 extends therethrough. An engagelllent element 364 is ad-
justably affixed near the end of the transverse shifter arm
354 so as to be engaged by the downwardly extendiny element
358 part way through the lateral movement of the casting bed
section 202 away from the casting bed section 204 at the
urging of the hydraulic cylinder 292.
1'he operation of the lost motion lin~age 356 ~
now be described beginning with the configuratioll illus-
trated in solid lines in FIG. 21 where the casting bed pal-
let lips 248 and 250 are in abutment, the piston rod 294
(FIG. 18) is fully extended, and the intermediate Eorm as-
semhly is in the lowered position shown in~FIG. 1~. By way
of example, and without limiting the scope of the invention,
the width of the intermediate form assembly 214 between the
points of engagement with the Lip5 24~ and 250 may be ~0
centimeters (FIG. 12 configuration). When the movable sec-
tion 202 is fully away from the ~ixed section 204, there is
a gap of 5 centimeters on each side of the intermediate form
assembly 214 (FIGS. 13 and 14 configuration). ~hus the
total transverse movement of the mova'~le section 202 fro~n
the single wide bed confiyuration of FIG. 15 to the fully-
away configuration is 50 centimeters.
As the piston rod 294 initially retracts, the only
movement is transverse movement of the movable bed 202 a~iay
from the fixed bed 204. During this initial movement, the
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transverse shi~ter arms 354 attached to the swing arm assem-
blies 3l8 and 320 do not move, ~ith the apertures 362 at the
end of the downwardly extending elements 353 sliding freely
along the transverse shifter arms 354. After the movable
casting bed section 202 llas moved through 45 centimeters of
its 50 centimeter travel, the downwardly extending element
358 engages the engagement element 364, to begin lateral
movement of the transverse shifter arms 354. This lateral
movement of the transverse shifter arms 354, whic~ results
in identical lateral movement of the swing arm asseMblies
318 and 320 and the intermediate form assembly 214, is 5
centimeters. At this point, the configuration of FIG. 14 is
reaclled, wherein the intermediate form assembly 314 may be
raised by actuating the hydraulic cylinders 322 (FIG. 19).
After the intermediate form assembly 214 has been
raised, the cylinders 292 are again operated to extelld the
piston rods 294 by 10 centimeters, resultin~ in the config-
uration of FIGS. 12 and 18.
To go from the configuration of FIGS. 12 and 18 to
the configuration of FIG. 13, the hydraulic cylinder 292 is
operated to retract tlle piston rod 294 its final 10 centi-
meters of movement. During the first 5 centimeters of this
movement, the intermediate form assembly 214 normally re
mains adjacent the fixed casting bed section 204, although
it is possible that greater adhesion with the cast concrete
member 206 ca~ried on the pallet 210 of the movable casting
bed section 202 would initially cause the center ~orm assem-
bly 214 to move with the movable bed 202. Ilowever, assuming
that the center form assembly 214 remains with the fixed
casting bed section 204, during the first 5 centimeters of
movement of the casting bed section 202 the lost motion
linkage 356 allows transverse shifter a~ns 354 to remain
stationary. For the final 5 centimeters of lateral movement
of the casting bed section 202, the lost motion linkage 356,
and particularly the elements 358 and 364 thereof, engage,
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pulling the transverse shi~ter arm 354 and causing lateral
movement of tlle intermediate form assembly 214.
In the event the intermediate form assembly 214
initially relnains adhered to the movable bed section 2n2 and
was pulled away from the fixed casting bed section 204 the
limit of travel of the sliding pivot asselnblies 324 326 and
334 is reached after 5 centimeters, stopping lateral Inove-
ment of the intermediate form assembly 214. The movable
casting bed section 202 then continues on for the final 5
centimeters of lateral movement.
With reference now to FIG. 22, the left side form
216 is illustrated, together with the extended cam actuator
276. An hydraulic cylinder 370 is arranged to longitudin-
ally move the extended cam actuator 276 and titereby effect
pivotal movement of the triangular actuator 264 (FIGS. 16
and 18) and the side form 21~ as wider surface portions 372
of the extended cam actuator 276 engage the sliding cam mem-
bers 270 in the manner described above with respect to the
previous embodlments.
From the foregoing, it will be apparent that the
present inven-tion provides a highly flexible and cost effi-
cient combination concrete bed casting apparatus Eor manu-
acturing concrete structural members in at least two dif-
ferent widths. This leads to optimum efficiency in opera-
tion by permitting single relatively wider slab sections to
be produced where the sections are to be cut into relatively
shorter lengths which may be lifted by the available crane
capacity, and which produces two relatively narrower slabs
simultaneously where longer finished lengtns are required
wllich would otherwise e~ceed tlle crane capacity of an asso-
ciated lifting crane.
While specific embodiments of the invention `nave
been illustrated and described herein it is realized tllat
modifications and changes will occur to those s~illed in
the art. It is tilerefore to be understood that the
Z7~32~
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appended clai.ms are intended to cover all such modif ic~tions
and changes as fall within the t~e spirit and scope of t~le
invention .
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