EP-4739848-A1 - CAISSON AND METHOD OF CONSTRUCTING A CAISSON

Abstract

Caisson comprising a top side and a bottom side, the bottom side being opposite the top side and each of the top side and the bottom side extending in a longitudinal direction and in width direction. A side wall extending in a height direction between the top side and the bot-tom side and enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface, and where the side wall comprises. A first longitudinal wall section extending in the longitudinal direction and a first transverse wall section extending in the width direction. Each of the first longitudinal wall section and the first transverse wall section comprises at least one curved portion having a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and wherein the side wall is made of concrete by additive manufacturing.

Inventors

• HOLM, MICHAEL

Assignees

• COBOD International A/S

Dates

Publication Date

20260513

Application Date

20230703

Claims (20)

1. 1. Caisson comprising: a top side and a bottom side, the bottom side being opposite the top side and each of the top side and the bottom side extending in a longitudinal direction and in width direction; a side wall extending in a height direction between the top side and the bottom side and enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface, and where the side wall comprises: a first longitudinal wall section extending in the longitudinal direction; and a first transverse wall section extending in the width direction ; wherein each of the first longitudinal wall section and the first transverse wall section comprises at least one curved portion having a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and wherein the side wall is made of concrete by additive manufacturing.
2. 2. Caisson according to claim 1, further comprising an inner support wall extending between wall sections of the side wall through the inner volume, thereby dividing the inner volume into at least two separate volumes.
3. 3. Caisson according to claim 2, wherein the side wall further comprises: a second transverse wall section, and a second longitudinal wall section, where each of the second transverse wall section and the second longitudinal wall section comprising at least one curved portion having a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and where the second longitudinal wall section extends in the longitudinal direction and the first and second transverse wall sections extend between the first and second longitudinal wall sections, and where the inner support wall extends between the first and second longitudinal wall sections.
4. 4. Caisson according to claim 3, comprising a plurality of inner support walls extending between the first and second longitudinal wall sections.
5. 5. Caisson according to claim 3 or 4, comprising one or more inner support walls extending between the first and second transversal wall sections.
6. 6. Caisson according to any one of claim 3 to 5, wherein the first and second transverse wall sections each have an overall curved shape curving outwards away from each other in the longitudinal direction.
7. 7. Caisson according to any one of claim 3 to 6, wherein each of the first longitudinal wall section, second longitudinal wall section, first transverse wall section and second transverse wall section comprises a plurality of the curved portions.
8. 8. Caisson according to claim 7, where the plurality of curved portions of the first transverse wall section is arranged in a first pattern of protrusions, and the plurality of curved portions of the second transverse wall section is arranged in a second pattern of protrusions, and where the first pattern and the second pattern are invers of each other.
9. 9. Caisson according to any one of claim 2 to 8, wherein at least one inner support wall comprises a recess or an opening.
10. 10. Caisson according to any one of the previous claims, further comprising a bottom plate to close off the bottom side.
11. 11. Caisson according to any one of the previous claims, wherein the side wall comprises at least X% concrete, measured by weight or volume.
12. 12. System comprising a first and a second caisson according to any one of the preceding claims; where the first caisson and the second caisson are arranged adjacent to one another with a wall section of the first caisson abutting a wall section of the second caisson, and where a gap between the wall section of the first caisson and the wall section of the second caisson is filled with concrete.
13. 13. Method of constructing a caisson comprising a top side, a bottom side, and a side wall extending between the top side and the bottom side, the side wall enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface; the method comprising the steps: printing a bottom layer of the side wall by extruding concrete from a printing head along a side wall printing path comprising a first longitudinal wall section extending in a longitudinal direction, and a first transverse wall section extending in a width direction; printing a plurality of subsequent layers of the side wall on top of the bottom layer and on top of each other; wherein each of the first longitudinal wall section and the first transverse wall section of the side wall printing path comprises at least one curved portion forming a convex side and a concave side of the side wall, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall.
14. 14. Method according to claim 13, further comprising printing an inner support wall by extruding concrete from a printing head along an inner support wall printing path extending between wall sections of the side wall through the inner volume.
15. 15. Method according to claim 13 or 14, wherein the side wall printing path further comprises a second transverse wall section and a second longitudinal wall section along, where each of the second transverse wall section and the second longitudinal wall section of the side wall printing path comprises at least one curved portion forming a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and where the second longitudinal wall section extends in the longitudinal direction and the first and second transverse wall sections extend between the first and second longitudinal wall sections.
16. 16. Method according to claim 15, further comprising printing a plurality of inner support walls by extruding concrete from a printing head along a plurality of inner support wall printing paths extending between the first and second longitudinal wall sections.
17. 17. Method according to claim 15 or 16, further comprising printing one or more inner support walls by extruding concrete from a printing head along one or more printing paths extending between the first and second transversal wall sections.
18. 18. Method according to any one of claim 15 to 17, wherein the first and second transverse wall sections of the printing path each have an overall curved shape curving outwards away from each other in the longitudinal direction.
19. 19. Method according to any one of claim 15 to 18, wherein each of the first longitudinal wall section, second longitudinal wall section, first transverse wall section and second transverse wall section comprises a plurality of the curved portions.
20. 20. Method according to claim 19, wherein the plurality of curved portions of the first transverse wall section is arranged in a first pattern of protrusions, and the plurality of curved portions of the second transverse wall section is arranged in a second pattern of protrusions, and where the first pattern and the second pattern are invers of each other.

Description

CAISSON AND METHOD OF CONSTUCTING A CAISSON Technical field The present invention relates to caissons and a method of constructing a caisson. Background Caissons are used in a wide range of engineering projects involving the construction of foundations, bridges, harbors, offshore structures, and other structures that require stable and secure support. The primary function of caissons is to provide structural support and stability, especially in challenging marine conditions. They transfer the loads from superstructure, such as quays, piers, or container terminals, to the underlying seabed or bedrock. This reduces the risk of excessive settlement, erosion, or structural failure, ensuring the safety and longevity of marine infrastructure, while providing stable foundations and protection against water ingress, allowing for the efficient handling of maritime traffic, loading and unloading of cargo, and safe docking of vessels. In the construction of ports and harbors, caissons are also used to create protective barriers, breakwaters, or retaining walls. Caissons are large structures typically comprising a number of watertight chambers and are either pre-fabricated or constructed in situ. They are strategically positioned to withstand the forces exerted by waves, currents, and tides. Traditional caissons are commonly constructed using reinforced concrete due to its durability, resistance to water permeation, and ability to withstand forces from a harsh marine environment. However, these conventional designs often present challenges in terms of transportation, installation, and maintenance due to their size and weight. Additionally, their construction requires large amounts of materials, such as concrete and steel rebars, making the construction time-consuming and costly. Therefore, there is a need for innovative caisson designs and/or construction methods that address at least some of these challenges. Summary According to a first aspect of the invention, this and other objects may be achieved with a caisson comprising a top side and a bottom side, the bottom side being opposite the top side and each of the top side and the bottom side extending in a longitudinal direction and in width direction; a side wall extending in a height direction between the top side and the bottom side and enclosing an inner volume, which is further delimited by the top side and the bottom side, where the side wall has an inner surface facing the inner volume and an outer surface opposite the inner surface, and where the side wall comprises a first longitudinal wall section extending in the longitudinal direction; and a first transverse wall section extending in the width direction; wherein each of the first longitudinal wall section and the first transverse wall section comprises at least one curved portion having a convex side and a concave side, where the convex side of each curved portion is part of the outer surface of the side wall and the concave side of each curved portion is part of the inner surface of the side wall, and wherein the side wall is made of concrete by additive manufacturing. By having each of the first longitudinal wall section and the first transverse wall section comprising at least one curved portion having a convex side as part of the outer surface of the side wall, the design of the caisson may offer improved force distribution and load bearing capabilities. Thereby allowing for less material use, and a cheaper and more environmentally friendly caisson. Further, the construction of the caisson by additive manufacturing may provide a faster and more optimized construction process, enabling design freedom of the caisson. The longitudinal direction and width direction expands a first plane, which will typically be a horizontal plane during the intended use of the caisson. The longitudinal direction and height direction expands a second plane, and the width direction and height direction expand a third plane, both typically be a vertical planes during the intended use of the caisson. Having the convex side of the curved portions of the side wall as part of the outer surface will allow the curved position to be in compression when a force is exerted on the curved portions from the outside of the caisson i.e., a direction transversal or perpendicular to the side wall. Plane or concave surfaces will at least partly be under tension when a caisson is submerges under water, and since concrete is stronger in compression than in tension it is desirable to increase the fraction of outside surface area which is under compression as much as possible and thereby increasing the strength to material ratio of the caisson. The curved portions may be arranged so that all of the side wall of the caisson will be in compression in a horizontal direction during it intended use. Thereby allowing for less material use in the design of the caisson while maintaining compressive strength. Concrete is understood as a material com