AU2009202374A1

AU2009202374A1 - Moulding apparatus for forming blocks made from concrete or other cured material

Info

Publication number: AU2009202374A1
Application number: AU2009202374A
Authority: AU
Inventors: Brian Reginald Turner
Original assignee: SOUTH EAST EXCAVATIONS NO 2 Pty Ltd
Current assignee: SOUTH EAST EXCAVATIONS (NO 2) Pty Ltd
Priority date: 2009-06-15
Filing date: 2009-06-15
Publication date: 2011-01-06

Description

P/00/011 Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title: "MOULDING APPARATUS FOR FORMING BLOCKS MADE FROM CONCRETE OR OTHER CURED MATERIAL" The following statement is a full description of this invention, including the best method of performing it known to us: 1 MOULDING APPARATUS FOR FORMING BLOCKS MADE FROM CONCRETE OR OTHER CURED MATERIAL This invention relates to moulding apparatus which can be used fro 5 the formation of blocks formed from cement or other cured material. Concrete blocks are used to form free standing and retaining walls. In such applications, the visible faces or faces of the block are provided with a textured or decorative appearance. Concrete blocks for forming walls are used in a variety of applications which mainly include retaining walls wherein 10 concrete blocks are stacked in horizontal rows called courses. Hitherto manufacture of concrete blocks has often been carried out by the dry cast process, which uses dry-cast block machinery to form blocks at a relatively high speed. In a typical dry cast block machine, settable material such as cement is fed into an open top mould from the top side. The 15 conventional mould consists of stationary sides to define the side walls of the block and an open bottom. A removable pallet is used to temporarily close the open bottom of the mould and form as a block forming operation. This conventional dry cast process, which is described in US Patent Publication 20080258340, uses a compression head which is forced 20 downwardly to compress the settable material after it has been poured into the mould to compact the material so as to conform to the internal shape of the mould. The compression head may have one or more shoes to define desired structural features in the required block. After removal of the pallet, the block is then removed from the mould through the open bottom. 25 Other conventional moulding apparatus for making concrete blocks for making a decorative or textured exposed face include US Patents 5,078,940, 5,217,630 and 6,224,815 which include the step of pouring uncured concrete or cement into a mould cavity and removing a cured block from the cavity while retaining a portion of the block to be retained in place relative to the 30 walls of a mould cavity to cause a split surface resembling natural stone. This process avoids a splitting operation to provide a textured or decorative exposed face as discussed in US Patent 6,321,470 and US Patent 2 3,981,953. However, all these processes are based on the conventional dry cast process which requires smooth cavity walls and the cured block to be removed from an open bottom face of the mould. This would be extremely difficult to do if the mould had a base supported at ground level. 5 Reference may also be made to US Patent 4,889,666 which describes a method for producing concrete blocks provided with inlaid patterns using a reusable mould having recessed patterns which are formed by applying ultra violet rays on the surface of a setting resin plate. US Patent 6,854,702 refers to the use of a form or casting machine 10 for manufacturing concrete blocks. The form includes a base and four side walls which are mounted on the base to pivot between a first position and a second position for removing a cast block from the form. An insert is secured to the base for forming one end surface of the block and inserts are attached to the side panels of the form for forming sides, top and bottom 15 surfaces of the block wherein the inserts are textured to form natural stone. US Patent 6,557,818 refers to similar subject matter. Thus, in summary of the prior art, such prior art moulds, casting apparatus or forms are complicated in operation in requiring that a cast block be removed from a bottom open end of the moulding apparatus or required 20 that a moulding apparatus have inserts to be placed inside the moulding apparatus to form a simulated or decorative pattern on one face of the moulded or cast block. The prior art also taught that in order to form a face resembling natural stone or split stone that it was necessary to have splitting apparatus inside the moulding apparatus or retain a portion of the block for a 25 splitting operation. It therefore is an object of the invention to provide moulding apparatus (which means forms and casting apparatus within its scope) which is effective in operation and is of simple construction. The moulding apparatus of the invention therefore includes: 30 (i) a body having a hollow interior which has a simulated pattern applied to a bottom surface thereof wherein said bottom surface forms part of a base wall which has at least a pair of sections which are relatively 3 moveable with respect to each other; (ii) a plurality of side frames or side walls which are adapted to be pivoted from a vertical operational position to a substantially horizontal non operational position; 5 (iii) a plurality of end walls or end frames which are adapted to be pivoted from a substantially vertical operational position to another non operational position which is angularly displaced from the vertical; and (iv) a plurality of mandrels or formers which are locatable within the hollow interior of the body to facilitate shaping of blocks formed from 10 concrete or other cured material after said settable material has been poured into the hollow interior. The body is preferably cuboidal in shape having an open top end and is preferably a pair of end walls or end frames and a pair of side frames or side walls. It is preferred that each side frame or side wall is pivotally 15 movable from a vertical operational position to a substantially horizontal position so as to facilitate movement of each mandrel from a position external of the body to an internal position within the body. Preferably each mandrel has a hollow interior so as to form a concrete block which also has a hollow interior. Each mandrel is desirable movable 20 into the internal operational position by forklifts or other suitable vehicle. More preferably each mandrel is attached to the forklift by a suitable fluid actuated device having a pair of pneumatically operated or hydraulically operated rams to maintain each mandrel in a horizontal plane which is initially transverse or normal to an adjacent side frame or side wall until the 25 mandrel is clear of the concrete block which has been formed within the body. This is important to avoid any disturbance or fracture of the concrete block which still requires considerable curing. There also may be provided a longitudinal partition which is located within the hollow interior of the body so as to form a pair of cast blocks. 30 There also may be provided a transverse partition which engages in a suitable socket or space located within the longitudinal partition so as to form four cast blocks.

4 Preferably each end wall may be operated by suitable fluid actuated means such as a hydraulic ram assembly or pneumatically operated ram assembly to move each end wall from the vertical operational position to a non-operational position angularly displaced from the vertical. 5 The base wall of the body may also have suitable fluid actuated means such as a hydraulic ram assembly to move each section of the base wall from a position wherein each section is abutting each other in an operational location or closed position to a non-operational location or open position wherein each section is spaced from each other. Preferably there 10 are a pair of these sections and the reason it is necessary to move each section from a closed position to an open position is to facilitate removal of the partially cured concrete block from the body. Reference may now be made to a preferred embodiment of the invention wherein: 15 FIG 1 is an exploded perspective view of moulding apparatus constructed in accordance with the invention showing the body of the mould in a fully open position; FIGS 2A and 2B show movement of the base wall sections of the moulding apparatus from open position to a closed position; 20 FIG 3 shows a perspective view of the moulding apparatus shown in FIG 1 with each end wall and each side frame in a vertical operational position and also showing movement of the mandrels into the hollow interior of the moulding apparatus; FIG 4 shows filling of the hollow interior of the moulding apparatus 25 shown in FIG 3 with a cement slurry; FIG 5 shows movement of the mandrels externally of the moulding apparatus shown in FIG 3 by an especially adapted hydraulically operated apparatus attached to a forklift vehicle; FIG 6 shows the hydraulically operated apparatus shown in FIG 5 in a 30 position with the hollow interior of the moulding apparatus; FIG 7 shows a similar view to FIG 6 with the mandrel partially removed from the hollow interior of the moulding apparatus; 5 FIG 8 shows a perspective view of the moulding apparatus with four concrete blocks formed in associated compartments after removal of all the mandrels; FIG 9 shows removal of the partially cured concrete blocks from the 5 hollow interior of the moulding apparatus; FIGS 10, 11 and 12 show operation of a rotary apparatus for rotating a concrete block to a position shown in FIGS 11 and 12 from a position shown in FIG 10; and FIGS 13, 14, 15 and 16 show perspective views of a hollow concrete 10 block formed by the moulding apparatus of the invention shown in FIGS 1 and 3. In FIG 1 there is provided a moulding apparatus 10 which has a body or frame 11 which incorporates a pair of opposed side frames 12 and a pair of opposed end doors 13. There is also provided a pair of base frames 14 15 each having a simulated moulded upper surface 15 which resembles a rock face or rock wall. There is also provided a skid assembly 16 having a pair of parallel skid members 17 and a skid plate or base plate 18 interconnecting each skid member 17. There is also provided a central longitudinal partition 19 having apertures 20. There is also provided a central removable 20 transverse partition 21 having a pair of wedge shaped body plates 22 which have side surfaces 23 that converge from top to bottom as shown in FIG 1. Partition 21 also has a top rail 24 to which is mounted a pair of support members 25 that have a purpose as hereinafter described. Each end wall 13 on its outer surface 25 has a pair of junction boxes 26 and a control 25 reinforced section 27 interconnecting a pair of opposed flanges 28. There is also provided a hydraulic ram assembly 30 for moving a pair of base frames 14 shown hereinafter in FIG 2. Each end door 13 is also provided with reinforced bottom rails 32 and a top reinforced rail 33. Each top rail 33 has a support member 34 which is clear of or spaced from link arms 35 of a 30 hydraulic ram assembly 36 wherein each link arm 35 is attached to an adjacent support bracket 37 which is welded to end wall 13 as shown. There is also provided junction box 38 on reinforced section 27. The central 6 removable partition 21 is also retained in vertical slot 39 of corresponding shape to partition 21. There is also shown locking members 40 which retain partition 21 in an operational position as shown in FIG 3. There is also provided a pair of mandrels 41 on each side of frame 11 5 which in operation are inserted through apertures 42 located in each of side frames 12 and also extend into aligned apertures 20 of central partition 19. Each mandrel when moved into operational position has a pair of locking pins 42 which may be moved by pneumatic cylinder 43 to extend through an adjacent aperture 44 and abut an interior surface 45 of each end door 13 in 10 the case of end pins 42 and abutting an adjacent surface 46 of each body plate 22 in the case of the pair of inner pins 42. Each locking pin 42 will therefore be present when the concrete blocks are poured as hereinafter described provide an elongate passage 42A extending through each of the concrete blocks as hereinafter described in FIGS 5 to 7. 15 From FIG 1 it therefore will be appreciated that the moulding or casting machine 10 is shown in a fully open position with side frames 12 pivoted to a non-operational position and thus lying on a floor or other horizontal support surface (not shown) and each end wall 13 also pivoted to an outer position which is at an acute angle to vertical as shown. Each of 20 mandrels 41 are withdrawn from frame 11 and surface 15 may be cleaned with a high pressure cleaner 15A and a concrete release agent also may be sprayed on each surface 15. In FIG 2A there is shown in a plan view each of side frames 12 in a non-operational position as shown in FIG 1 of each of end walls 13 also in a 25 non-operational position as shown in FIG 1. Each of base frames 14 are shown in a position spaced from central longitudinal partition 19 by gap 47. Subsequently upon closure of end walls 13 and each of side frames 12 as shown in FIG 2B each of base frames 14 have moved inwardly to close gap 47 by hydraulic cylinder assemblies 30 each having a cylinder 48 and piston 30 rod 49. FIG 3 shows that mandrels 41 shown schematically may be moved into compartments 50 in frame 11 by forklift bars 51. Each of mandrels 41 7 may be retained in desired position by apertures 20 shown in FIG 1 and held in place by a retaining flange (not shown). Each of side frames 12 may be locked in position by wedge shaped fasteners 52 and 53 engaging mating support brackets 54 and 55. One mandrel 41 is shown retained in 5 compartment 50 and extending into mating aperture surface 20 of longitudinal partition 20 adjacent perimeter 56 of longitudinal central partition 19. There is also provided pivot joints 57 for each side frame 12. There is also provided control panel 58 mounted on support post 59. Apertures 20 have been omitted from FIG 3 for the sake of clarity. In FIG 3 there is also 10 shown loops or hooks 59A formed from rebar or other suitable material being suspended from support members 34 and 25 already described in FIG 1. The purpose of the rebar loops or hooks 59A is described in FIG 9. In FIG 4 there is shown a concrete slurry or cement slurry 60 being poured into each compartment 50. This is done by concrete truck 61 having 15 a rotating barrel 62 wherein the slurry 60 is poured into compartment 50 through chute 63. It will also be noted that it is desirable to vibrate the surface 60A of slurry 60 with a vibratory tool such as a jackhammer 64 to prevent air pockets being formed in slurry 60. The top surface 60 may then be trowelled 20 to provide a flat top surface 60A and the slurry 60 may then be cured inside compartments 60 for 1 to 2 hours. Jackhammer 64 may be provided with an air hose 65. In FIGS 5 to 7 there is shown extraction machine 70 which has a frame 71 having a pair of opposed stop members 72 which each abut with 25 an adjacent location on side frame 12 when in the position shown in FIG 6. The extraction machine 70 is also provided with a pair of hydraulic cylinder assemblies 73 and 73A and a pair of hydraulic cylinder assemblies 74 and 74A mounted to extraction machine 70 as shown. The extraction machine 70 is attached to adjacent tynes 72A and 72B of forklift vehicle though hollow 30 sockets 72C and 72D as shown in FIG 5. Hydraulic cylinder assemblies 73 and 73A are provided with cylinder 77, piston rod 78 and piston 79 as shown. Hydraulic cylinder assemblies 74 8 and 74A are provided with cylinder 80, piston rod 81 and piston 82 as shown. Each hydraulic cylinder assembly 74 and 74A are pivotally attached to frame 71 at 83 and 84. Each hydraulic cylinder assembly 73 and 73A are pivotally attached to frame 71 at 86 and 87. The adjacent pistons 79 and 82 as 5 shown have a connection pin 88 best shown in FIG 6 which engages in recess 69 on each side of mandrel 41 as shown in FIG 6. Subsequently as shown in FIG 7 upon movement of forklift vehicle 72 away from frame 11, mandrel 41 is now partially withdrawn from frame 11. This movement is facilitated by extraction machine 70 each having cylinders 10 80 being inclined inwardly to an adjacent internal surface of mandrel 41 as shown at 89 in FIG 5. It is important during the mandrel extraction procedure as shown in FIGS 5, 6 and 7 that the mandrels are extracted in the orientation as shown so that minimal disturbance is caused to concrete blocks 66. It also will be 15 appreciated that it is the continued operation of hydraulic cylinder assemblies 73 and 73A and 74 and 74A that provide the desired parallel movement of each mandrel 41 from frame 11. In FIG 8 there are now shown the formation of four concrete blocks 66 in each compartment 50 of frame 11 with rebar loops 59A extending above 20 the top surface 60A of each of blocks 66 as shown. Thus FIG 8 shows removal of the central partition 19 which has wedge shaped body plates 22. Tie straps 90 are now placed on each of end doors 13 to prevent undesired outer movement of each end door 13 from the position shown in FIG 1. Each tip strap 90 is attached to retaining members 91 and 92. The tie straps 25 90 may be tightened or made rigid by operation of hydraulic ram assemblies 36. Locking wedges 52 and 53 and 94 may now be removed to allow each side frame 12 to be moved to the non-operational position shown in FIG 1. Locking wedges 93 may also be removed from each end door 13 to 30 allow each end door 13 to attain the position shown in FIG 1. The straps 90 are useful as a precautionary measure if hydraulic ram assemblies fail in retaining each end door 13 in the desired position. This 9 also applies to locking wedges 93. In FIG 9 there is shown removal of concrete blocks 66 from moulding or casting machine 10 by crane wherein there is provided a spreader bar 95 having chains 96 and 97 linked to each end spreader bar 95 defined by 5 retainers 100. The spreader bar has shackles 98 and 99 which each engage with rebar loops 59A. The crane (not shown) has a suspension hook 101 having ring 102 that engages with chains 96 and 97. It will also be noted that each concrete block 66 has a hollow interior 103 and also has an outwardly extending rib 104. Ribs 104 are formed during the casting or moulding 10 process using machine 10 by internal recesses 105 formed in each internal surface of side frames 12. Recesses 124 are formed by ribs 40A shown in FIGS 1 and 9. After removal of concrete blocks 66 from moulding machine 10 they are then placed on a rotary machine 107 shown in FIGS 10, 11 and 12. 15 Rotary machine 107 has a base frame 108, a rotatable cradle 109 for rotation of concrete blocks 66, side uprights 110 each having an angled pillar 111 for supporting an adjacent hydraulic ram assembly 112 which has an end clevis 113 attached to bracket 114 of angled pillar 111, cylinder 115, piston rod 116 and attached to pivot joint 117 of rotatable cradle 109 and 20 hydraulic fluid hoses 118 and 119. The rotatable cradle 109 is supported at each end by hydraulic ram assemblies 112 as shown in FIG 12. Upon actuation of each hydraulic ram assembly 112, block 66 may be rotated from the position shown in FIG 9 after deposition in the cradle 109 by the crane to the position shown in FIGS 11 and 12 with the rebar loops 59A extending 25 from a side surface of concrete block 66 as shown in FIG 12. The rotatable cradle 109 also has support bars 120 which support concrete block 66 in the position shown in FIG 12. The base frame 108 includes side frame members 121 each having crane lifting lugs 122 and front and rear frame members 123. It will be noted that concrete block 66 30 may be readily shifted from the position shown in FIG 10 to the position shown in FIGS 11 and 12 by actuation of hydraulic assemblies 112 each causing rotation of cradle 109 as shown by the arrow in FIG 10.

10 The concrete blocks 66 may then be removed from rotation machine 107 by forklifts 51 and placed in a holding yard for curing. Each concrete block 66 as shown in FIGS 13, 14,15 and 16 includes a hollow interior 103, outwardly extending rib 104 and a mating recess 124 5 also formed in moulding machine 10 by rib 40A shown in FIG 1. The block 66 also has a simulated rock face 125 and rebar loops 59A. The block 66 also has planar end faces 126 and a planar bottom face 127. From the foregoing it will be appreciated that the moulding apparatus as described above in the preferred embodiment is extremely efficient in 10 operation and is simple in structure. It is especially adapted for manufacture of concrete blocks which weigh in excess of 2.5 tonnes compared to conventional methods wherein the concrete blocks would have to be manually handled and these would have a maximum weight of 100 kilograms. 15 It therefore will be appreciated that in another aspect of the invention there is provided a process of moulding or forming a block formed from concrete or other cured material which includes the steps of: (i) pouring the concrete or other cured material in an uncured state or slurry into a moulding apparatus having a hollow interior which has a 20 simulated or textured bottom surface formed by a base wall having a plurality of sections which are in abutting relationship and wherein said hollow interior is occupied by one or more mandrels or formers which are responsible for forming an internal space in each hollow block; (ii) moving the plurality of base wall sections away from each other 25 to facilitate removal of the at least partially cured concrete blocks from the hollow interior of the moulding apparatus; (iii) removing said one or more mandrels from the hollow interior of the moulding apparatus by optionally fluid actuated apparatus attached to or associated with a vehicle for ensuring that each mandrel is retained in a 30 position normal to a side wall or frame of the moulding apparatus when in a state of at least partial withdrawal from the moulding apparatus to avoid disturbance to an adjacent partially cured concrete block; and 11 (iv) withdrawing the or each concrete block from the moulding apparatus.

Claims

1. Moulding apparatus for formation of blocks formed from cement or other cured material which includes: (i) a body having a hollow interior which has a simulated pattern 5 applied to a bottom surface thereof wherein said bottom surface forms part of a base wall which has at least a pair of sections which are relatively moveable with respect to each other; (ii) a plurality of side frames or side walls which are adapted to be pivoted from a vertical operational position to a substantially horizontal non 10 operational position; (iii) a plurality of end walls or end frames which are adapted to be pivoted from a substantially vertical operational position to another non operational position which is angularly displaced from the vertical; and (iv) a plurality of mandrels or formers which are locatable within the 15 hollow interior of the body to facilitate shaping of blocks formed from concrete or other cured material after said cured material has been poured into the hollow interior.

2. Moulding apparatus as claimed in claim 1 wherein the body is cuboidal in shape having an open top and a pair of end walls or end frames 20 and a pair of side walls or side frames.

3. Moulding apparatus as claimed in claim 2 wherein each side frame or side wall is pivotally movable from a vertical operational position to a substantially horizontal position so as to facilitate movement of each mandrel from a position external of the body to an internal position within the body. 25

4. Moulding apparatus as claimed in claim 1 or 2 wherein each mandrel has a hollow interior so as to form an associated concrete block which also has a hollow interior.

5. Moulding apparatus as claimed in claim 3, wherein each mandrel is movable into the internal position by forklifts or other suitable vehicle. 30

6. Moulding apparatus as claimed in claim 5 wherein each mandrel is attached to said vehicle by a fluid actuated device having a pair of pneumatically operated or hydraulically operated rams to maintain each 13 mandrel in a horizontal plane which is initially transverse or normal to an adjacent side frame or side wall of the body until the mandrel is clear of the concrete blocks which has been formed within the body.

7. Moulding apparatus as claimed in any one of claims 1 to 6 wherein 5 there is a transverse partition located within the hollow body so as to form a pair of concrete blocks.

8. Moulding apparatus as claimed in claim 7 wherein the longitudinal partition has a plurality of apertures corresponding to the number of blocks that are required wherein in an inner part of each mandrel locates within an 10 associated aperture when located within the hollow interior of the body.

9. Moulding apparatus as claimed in claim 7 or 8 wherein there is also provided a transverse partition which engages in a suitable socket or space located within the longitudinal partition so as to increase the number of concrete blocks being formed. 15

10. Moulding apparatus as claimed in any one of claims 1 to 9 wherein each end wall is operated by suitable fluid actuated means to move each end wall from the vertical operational position to the non-operational position which is angularly displaced from the vertical.

11. Moulding apparatus as claimed in any one of claims 1 to 10 wherein 20 each base wall section is movable by a hydraulic ram assembly from a closed position wherein each base wall section abuts each other to an open position wherein each base wall section is spaced from each other.

12. Moulding apparatus as claimed in any one of claims 1 to 11 wherein each mandrel is provided with a fluid actuated engagement pin in a hollow 25 interior thereof which in use engages with an adjacent hollow block so as to form a pair of hollow passages located in each end wall of the hollow block.

13. Moulding apparatus as claimed in any one of claims 1 to 12 wherein the body is-provided with a plurality of support members each located on at least each end wall to support a loop or hook of rebar or other rigid material 30 which is located in each hollow block in a side surface thereof so as to enable each hollow block to be lifted out of the body when in at least a partially cured condition. 14

14. Moulding apparatus as claimed in claim 7 wherein the transverse partition has a plurality of support members to support the loop or hook of rebar or other suitable rigid material which is located in each hollow block in a side surface thereof so as to enable each hollow block to be lifted out of 5 the body when in at least a partially cured condition.

15. Locking apparatus as claimed in any one of claims 1 to 14 wherein there is provided locking pins or locking wedges to lock each end wall or frame and each side wall or frame when in the vertical operational position.

16. A process of moulding of forming a block formed from concrete or 10 other cured material which includes the steps of: (i) pouring the concrete or other cured material in an uncured state or slurry into a moulding apparatus having a hollow interior which has a simulated or textured bottom surface formed by a base wall having a plurality of sections which are in abutting relationship and wherein said hollow interior 15 is occupied by one or more mandrels or formers which are responsible for forming an internal space in each hollow block; (ii) moving the plurality of base wall sections away from each other to facilitate removal of the at least partially cured concrete blocks from the hollow interior of the moulding apparatus; 20 (iii) removing said one or more mandrels from the hollow interior of the moulding apparatus; and (iv) withdrawing the or each concrete block from the moulding apparatus.

17. A process as claimed in claim 16 wherein in step (iii) each mandrel is 25 retained in a position normal to a side wall or frame of the moulding apparatus when in a state of at least partial withdrawal from the moulding apparatus to avoid disturbance to an adjacent partially cured concrete block.

18. A method as claimed in claim 17, wherein each mandrel is attached to fluid actuated apparatus attached to or associated with a vehicle which 30 facilitates the movable of said one or more mandrels.

19. A method of moulding a concrete block formed from concrete or other suitable cured material which includes the steps of: 15 (i) lifting each block from the moulding apparatus after each concrete block has been formed and wherein each block is formed from at least partially cured concrete or other material by engagement of chains or cables with an upwardly extending loop or hook made from rebar or other 5 suitable rigid material embedded in each block; and (ii) rotating each block from a position wherein each loop or hook is located in a top surface of each concrete block to an orientation wherein each loop or hook is located in a side surface of each concrete block.

20. Blocks formed from concrete or other cured material from the process 10 of claim 18 or 19.