GB2562313A

GB2562313A - Piling template apparatus and method of piling utilising same

Info

Publication number: GB2562313A
Application number: GB1707702.5A
Authority: GB
Inventors: Coupe Robert
Original assignee: Volkerstevin Ltd
Current assignee: Volkerstevin Ltd
Priority date: 2017-05-12
Filing date: 2017-05-12
Publication date: 2018-11-14
Anticipated expiration: 2037-05-12
Also published as: GB2562313B; GB201707702D0

Abstract

A piling template apparatus 100 for positioning a pile 60 to be installed in a piling operation, the said pile being a next pile 60N of an array of piles being installed in the piling operation. Wherein the template apparatus comprises engagement means 140 for engaging and supporting the said next pile in a desired location and orientation in which it is to be installed, support means 160 for supporting the template apparatus on one or more other piles 60P of the array already installed in the piling operation. The template apparatus further including transportation means 180 for transporting the template apparatus from a first installation position in which it is supported on one or more already installed piles of the array or series and at a location defining an installation location of a previously installed pile, to a second installation position in which it defines an installation location for the said next pile to be installed in the array.

Description

PILING TEMPLATE APPARATUS AND METHOD OF PILING UTILISING SAME

TECHNICAL FIELD

This invention relates to a piling template apparatus and its use in a method of piling. More particularly, though not exclusively, the invention relates to a template apparatus which is usable in the positioning and installation of piles in the building of reinforcing or protective or space-defining structures, especially though not exclusively in marine settings. The invention also relates to methods of positioning and installing piles using the template apparatus, as well as to structures built using the method.

BACKGROUND OF THE INVENTION AND PRIOR ART

In the fields of civil and marine engineering, the construction of reinforcing or protective or space-defining structures, especially in marine settings, common involves building such structures using combination wall systems (commonly known as “combi-wall” systems). Such structures may typically take the form of harbour walls, docks, berths, piers, dams or other marine or waterside structures, or may even be employed in land reclamation and the building of bridges, foundations or buildings themselves. A fundamental feature of such combi-wall systems is the installation early on in the project of an array or series of vertical piles, i.e. generally hollow, and usually cylindrical, tubes or columns, typically of steel, into the seabed or other ground for supporting the remainder of the structure. In the case of combi-walls in marine settings, once the main piles have been so installed, sheet piles in the form of infilling steel sheets are then inserted between the main piles to complete the structure. And in the case of other types of structure, once the main piles have been so installed, other components or stages of the overall project can then be progressed above the supporting piles.

In the case of marine piling, especially that involving the installation of piles in the seabed some distance offshore or perhaps even just a short distance from land, it is typically necessary to employ one or more floating barges, platforms or vessels as a general operating base, as well as to provide a supply or storage repository for piles yet to be installed, a base for supporting a crane used to lift piles into position and a base for supporting a hydraulic hammer device used to drive the piles into the seabed once they have been correctly positioned. For the purpose of positioning each pile in readiness for being hammer-driven into the seabed, and further to maintain the pile in position whilst being so hammer-driven, a template structure or apparatus is generally used. Conventionally such templates comprise a rigid metal frame structure which is built in situ, often being attached to an existing pile as a reference point and a means of support, to define the correct position of a next pile to be installed. The template structure is configured to surround and hold the pile in position while it is installed, and once a given pile has been installed using the template as a guide, the template structure is then dismantled and/or moved to its next position ready for installing the next pile in the array or series. A problem associated with such known piling template structures is that they are inefficient to use. In particular, since they need constructing in situ or at least partial dismantling and reassembling in each new position in which a new pile position is needed to be defined, they lead to slow turnaround times between each pile’s installation in the overall sequential piling operation. This can have significant economic ramifications, especially since the daily cost of an overall marine piling project involving heavy and expensive machinery and equipment and numerous personnel can be high. And particularly in the case of piling projects involving large numbers of piles that need to be installed as efficiently and accurately as the project requirements dictate, the construction and manner of use of known template structures lead to inefficient, undesirably slow and disadvantageously uneconomical piling operations.

There is therefore a need in the art of piling, especially marine-based piling, for an improved and more efficient templating system for defining and controlling the position of each pile as it is prepared for installation and during its installation. Any proposal to meet this need desirably should not compromise the accuracy and stability with which a pile can be positioned and installed in its desired location, yet be able to be moved from one piling position to the next in a given array or series in a more efficient manner than hitherto been possible using conventional piling template structures. It is with a primary object of addressing this need that the present invention has been devised.

Other objects and advantages of the invention or embodiments thereof may be apparent from the further definitions and descriptions which follow below of embodiments of the invention and particular features thereof.

SUMMARY OF THE INVENTION

Embodiments of the invention in its various aspects may be understood with reference to the appended claims.

In various of its aspects the present invention provides a piling template apparatus, a method of positioning and/or supporting a pile before and/or during installation using the apparatus, a method of piling utilising the apparatus, an array or series of piles installed using the apparatus, and a structure incorporating piles installed using the apparatus.

In one aspect of the present invention for which protection is sought there is provided a piling template apparatus for positioning and/or supporting a pile to be installed in a piling operation, the said pile being a next pile of an array or series of a plurality of piles being installed in the piling operation, wherein the template apparatus comprises: engagement means for engaging and supporting the said next pile in a desired location and/or orientation in which it is to be installed, and support means for supporting the template apparatus on one or more other piles of the array or series already installed in the piling operation; wherein the template apparatus includes transportation means for transporting the template apparatus from a first installation position in which it is supported on one or more already installed piles of the array or series and at a location defining an installation location of a previously installed pile, to a second installation position in which it is supported on one or more already installed piles of the array or series and in which it defines an installation location for the said next pile to be installed in the array or series.

In another aspect of the present invention for which protection is sought there is provided a method of positioning and/or supporting a pile before and/or during installation thereof in a piling operation, the said pile being a next pile of an array or series of a plurality of piles being installed in the piling operation, the method comprising: providing a piling template apparatus according to the preceding aspect of the invention or any embodiment thereof, the template apparatus being positioned in a first installation position in which it is supported on one or more already installed piles of the array or series and at a location defining an installation location of a previously installed pile; operating the transportation means so as to transport the template apparatus from the said first installation position into a second installation position in which it is supported on one or more already installed piles of the array or series and in which it defines an installation location for the said next pile to be installed in the array or series; and inserting the said next pile into the engagement means of the apparatus and actuating the engagement means so as to engage and support the said next pile in the said desired location and/or orientation in which it is to be installed.

In yet another aspect of the present invention for which protection is sought there is provided a method of piling, in which a plurality of piles are installed in an array or series thereof, the method comprising: (i) providing a piling template apparatus according to the first-mentioned aspect of the invention or any embodiment thereof, and positioning the template apparatus in a first installation position in which it is supported on one or more already installed piles of the array or series and defines a first installation location for a first new pile of the array or series; (ii) actuating the engagement means so as to engage and support the said first new pile at the said first installation location and/or in a desired orientation in which it is to be installed at that first installation location; (iii) installing the said first new pile; (iv) operating the transportation means of the template apparatus so as to transport the template apparatus from the said first installation position into a second installation position in which it is supported on one or more already installed piles of the array or series including the said installed first new pile and in which it defines a second installation location for a second new pile to be installed of the array or series; (v) inserting the said second new pile into the engagement means of the apparatus and actuating the engagement means so as to engage and support the said second new pile at the said second installation location and/or in a desired orientation in which it is to be installed at that second installation location; and (vi) installing the said second new pile.

In practical embodiments of the above-defined method of piling, steps corresponding to (iv), (v) and (vi) may be repeated as many times as may be necessary with respect to any number of new piles, e.g. third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, and so on upwards in number, that may be desired in the installation of the total number of piles in the overall piling operation. In embodiments the total number of piles that may installed in the piling operation using the template apparatus may be unlimited.

In a yet further aspect of the present invention for which protection is sought there is provided an array or series of piles installed using the template apparatus of the first-mentioned aspect of the invention or any embodiment thereof, or installed according to the method of piling of the preceding aspect.

In another yet further aspect of the present invention for which protection is sought there is provided a structure, e.g. a marine structure such as a combi-wall, incorporating piles installed using the template apparatus of the first-mentioned aspect of the invention or any embodiment thereof, or installed according to the method of piling of the preceding-but-one aspect.

In many embodiments of the invention in its various aspects the piling operation or the method of piling, as the case may be, may be a sequential such operation or method, in which a plurality of piles are installed one after another in a linear sequence or row. That linear sequence or row may in some practical implementations be a generally substantially straight line of the said plurality of piles. Alternatively, in other practical implementations that linear sequence or row may be generally substantially curved, arcuate, convoluted or otherwise regularly or irregularly shaped in any desired form. In any such cases the sequence or row of piles may be generally continuous or it may be discontinuous. In any given sequence or row the piles may be generally substantially uniformly or evenly or equidistantly spaced, or they may be arranged in groups, with adjacent groups being spaced by a distance which is larger or smaller than the spacings between individual piles within each group.

It is a general feature of embodiments of the invention in its various aspects that in essence the template apparatus may be transportable from one pile installation position or location to the next pile installation position or location in a sequential, staged, stepwise or incremental manner, wherein each stage or step or increment of the transportational movement of the apparatus takes place between individual installation operations of respective individual piles as the overall piling operation progresses. Thus, once a given individual pile has been installed, having been engaged and supported by the engagement means of the template apparatus whilst the apparatus is in a given installation position defining the installation location of that given pile, the apparatus may then be transported to its next installation position defining a next installation location of a next pile, and that next pile may then be installed at that next installation location whilst being engaged and supported by the engagement means of the apparatus now in that next installation position. This procedure may then be repeated as many times as may be necessary for installing each pile of the plurality thereof, with the template apparatus being transported from each installation position or location to the next one between each pile’s installation stage of the operation.

Accordingly, in some embodiments the template apparatus may be transportable at least in a forward direction of travel, which forward direction of travel corresponds to a direction in which a next pile installation location lies relative to a current or a previous, especially an immediately previous, pile installation location. Thus, and conversely, in some embodiments the template apparatus may be transportable at least in a direction of travel opposite to a rearward direction in which a current or a previous, especially an immediately previous, pile installation location lies relative to a next pile installation location.

Thus, looked at possibly more simply, in yet another aspect of the present invention for which protection is sought there is provided a piling template apparatus for defining a pile installation location in a piling operation, the template apparatus comprising: engagement means constructed and arranged for engaging and supporting a pile to be installed at the said pile installation location; support means constructed and arranged for supporting the template apparatus on one or more other piles already installed in the piling operation; and transportation means constructed and arranged for transporting the template apparatus relative to one or more of said other piles.

In some embodiments of the above-defined apparatus the transportation means may be constructed and arranged for transporting the template apparatus relative to one or more of the other piles from a first installation position relative to those other piles to a second installation position relative to those other piles, the second installation position corresponding to the said pile installation location.

In some such embodiments the second installation position of the template apparatus may be forward of the first installation position, i.e. the second installation position may be displaced relative to the first installation position in a direction corresponding to the forward direction in which successive piles are to be installed sequentially in the piling operation.

In many embodiments of the invention in its various aspects the transportation means may desirably be constructed and arranged for transporting the template apparatus from the first installation position to the second installation position in a translational manner, i.e. in moving from the first to the second installation position the template apparatus travels relative to the said other piles in a substantially linear path or direction, especially substantially without any significant or appreciable transverse or rotational displacement relative to its axis of forward movement.

However, in other embodiments of the invention in its various aspects it may be possible for the transportation means to be constructed and arranged for transporting the template apparatus from the first installation position to the second installation position in a pivoting or rotational manner, in particular for example by the template apparatus undergoing pivoting or rotational movement, relative to the said other piles, about a pivot or rotational axis which is generally substantially vertical or parallel to the general longitudinal length axes of the piles.

In some embodiments of the present invention in its various aspects the template apparatus may comprise a main frame constructed and arranged for housing and/or carrying and/or supporting at least some of the components of at least one or more of the engagement means, the support means and the transportation means. In particular, the main frame may carry and have attached thereto at least the engagement means, so that the engagement means is constrained to move with the main frame in any particular direction in which it may move or be driven, especially by the transportation means. Such a main frame may be constructed from any suitable arrangement and number of interconnected frame members or elements, and optionally may include any suitable attachment or mounting devices or arrangements for carrying, anchoring or otherwise providing the various respective components of the apparatus therein, as desired or appropriate or necessary. Accordingly, the main frame may be designed to have sufficient strength and rigidity to provide a sufficiently strong and stable framework for enabling the template apparatus to be supported and transported, and the engagement means to function, in a stable manner.

Alternatively or additionally to the main frame, in some embodiments of the present invention in its various aspects the template apparatus may comprise, independently of a main frame, a clamp frame constructed and arranged to provide and/or carry and/or support at least some of the components of at least one or more of the support means and the transportation means. Embodiment constructional arrangements of the clamp frame and its function will be discussed further hereinbelow.

Alternatively or additionally to the main frame and/or the clamp frame, in some embodiments of the present invention in its various aspects the template apparatus may comprise, independently of a main frame and/or a clamp frame, a stamp frame constructed and arranged to provide and/or carry and/or support at least some other components of at least one or more of the support means and the transportation means. Embodiment constructional arrangements of the stamp frame and its function will be discussed further hereinbelow.

In many practical embodiments of the apparatus of the present invention the engagement means may be provided or located at a forward end of the apparatus, which is to say an end of the apparatus in the direction of which the apparatus is designed to travel under operation of the transportation means in moving it from one pile installation position or location to the next.

In some embodiments of the present invention the engagement means of the template apparatus may comprise an engagement device including: one or more engagement members constructed and arranged for engaging and supporting a pile placed in the device; and one or more adjustment devices each constructed and arranged for acting on the or a respective one of the engagement members for adjusting or modifying the position and/or orientation of the said pile placed in the device relative to the remainder of the apparatus.

In some such embodiments the engagement device may include a plurality of the said engagement members, with each said engagement member being provided with a respective associated one of a plurality of the said adjustment devices.

In some practical forms of the above-defined engagement device, the or each engagement member may comprise a roller or other bearing member or element which is arranged to abuttingly engage an outer wall or surface of a pile that is placed in the device in order to be positioned and supported thereby. The roller or other bearing member may or may not be driven by a drive means, e.g. a motor, for example in order to provide some degree of control of movement or restriction or hindrance of movement of the pile (e.g. against the force of gravity) once it has been placed in the device. Generally, however, the or each roller may be mounted and arranged to maintain its respective abutting engagement with the outer wall or surface of the pile as the pile passes downwardly relative to and through the engagement device as it is installed in its predefined and controlled position and/or orientation.

In some practical forms of the above-defined engagement device, the or each adjustment device may comprise a piston-in-cylinder device constructed and arranged for controlling and/or adjusting and/or altering to any extent necessary the position, relative to the or the respective pile, of the or the respective one of the engagement members, especially the extent of its extension or retraction. The or each piston-in-cylinder device may for example be hydraulically powered and operated, and appropriate supply and control means for operating same may be provided at an appropriate location elsewhere in the apparatus, or possibly even remotely therefrom.

In some practical forms one or more, especially a plurality of, e.g. two, groups of such engagement members and associated adjustment devices may be provided in the engagement device of the apparatus, wherein each group is spaced apart from the other(s) in a generally substantially vertical direction (or a direction parallel to the general longitudinal length axes of the piles). Each group may comprise two or more, especially for example 3 or 4, such engagement members and associated adjustment devices, especially arranged equi-angularly or equidistantly or symmetrically around the vertical or longitudinal direction/axes. By this three-dimensional arrangement of such a plurality of the various engagement members and associated adjustment devices, the degree to which the position and, especially, orientation of a pile placed in the engagement device may be controlled and/or adjusted may be optimised. In many such embodiments the arrangement of engagement members and associated adjustment devices may be such as to permit control and/or adjustment of any given pile’s position and/or orientation in or with respect to any one or more of, and especially all of, a longitudinal axis (i.e. an axis parallel to the defined forward direction of travel of the apparatus), a transversal axis (i.e. an axis perpendicular to the longitudinal axis), a vertical axis, and a pitch angle or angle of incidence relative to a vertical axis in any direction around that vertical axis. Other numbers and/or spatial positionings of engagement members and associated adjustment devices may however be employed if desired or appropriate.

In this connection it is to be understood that it may be important in a sequential piling operation that, as each next pile is installed, any error or tolerance in the position or orientation of any one individual pile is not compounded or accumulated in the positioning and orienting of a next pile whose position and/or orientation may be dependent on or defined by or with reference to that of the previous pile. This is especially since in many embodiments one or more previously installed piles may be used to support the template apparatus whilst the next pile’s installation position and/or orientation is defined by the engagement device of the apparatus. In this manner any accumulation of error in the placement position and/or orientation of each new pile to be installed may be minimised or possibly even substantially eliminated. In practical example embodiments the position and orientation of a given pile placed in the engagement device of the template apparatus may be detected or measured by any number of suitable detector or measurement device(s) (e.g. one or more mechanical, optical or electronic position detection devices) and an output produced thereby may then be used to control, e.g. via an appropriate control device of the apparatus’ overall control system, the respective adjustment devices.

In many practical embodiments of a piling operation carried out in accordance with the present invention and using the template apparatus thereof, it may often be that successive piles are installed so as to be generally substantially or approximately parallel to each other, whereby there results an array or series of installed piles all having substantially or approximately the same orientation relative to the seabed or other surface or ground in which the piles are anchored.

In practical implementations of the present invention, for the actual installation of a given or each pile, a force transmission device may be used to apply force to an upper end or wall or mouth of the pile to mechanically force it into the seabed or other surface or ground into which the pile is to be anchored. A hammer device, e.g. a hydraulically powered and operated hammer device, may be used for this purpose, examples of which are well-known in the art. The hammer device may be provided and operated and controlled separately and/or remotely from the template apparatus itself, e.g. via a crane from a platform or vessel located alongside or adjacent the piling site, as is conventionally the case in known piling operations.

For the purpose of maintaining engagement or contact between the hammer device and the upper end of the pile during the hammering insertion operation, in some embodiments the engagement device of the template apparatus may be constructed and arranged to define a hollow space therewithin once a pile has passed a certain point therethrough during its downward insertion movement under the action of the hammer device, through which hollow space the hammer device can itself pass as it completes its hammering operation on the upper end of the pile. For this purpose, in some embodiments of the invention the or each of the aforementioned adjustment devices may be retractable, especially retractable in a direction transverse to the longitudinal axis of the pile, especially during a latter or final stage of the pile insertion operation, by which stage the pile’s overall position and orientation will have been assured during the earlier stages of its insertion operation.

Likewise, in practical implementations of the present invention, a crane located on a platform or vessel located alongside or adjacent the piling site may be used to lift each respective new pile into position and placing it in or into, and lowering it at least partially through, the engagement means of the template apparatus once it has been transported into its next new installation position defining the next new pile installation location of that respective new pile. This pile placement step using a crane may be substantially in accordance with known and conventional techniques.

In many practical embodiments of the apparatus of the present invention the support means may be provided or located at least in a median region or portion of the apparatus, and/or possibly at least in part in a rearward facing or extending (i.e. towards an end distal from the end at which is provided the engagement means) region or portion of the apparatus. In some such embodiments the support means may be provided in a major proportion of the apparatus which is other than that region or portion thereof that comprises the engagement means.

In some embodiments of the present invention the support means of the template apparatus may comprise a supporting arrangement comprising one or more support members or support devices which are constructed and arranged for supporting the template apparatus on the one or more other piles of the array or series previously installed in the piling operation. In addition to their supporting function, the one or more support members or support devices may be constructed and arranged for releasably anchoring the template apparatus on the one or more already installed piles.

In some such embodiments the supporting arrangement may comprise the above-mentioned clamp frame. In some embodiments the supporting arrangement may be dimensioned, constructed and arranged for supporting and releasably anchoring the template apparatus onto upper portions or upper end regions or faces or upper wall portions of one or more of the already installed piles. It may be particularly desirable for the supporting arrangement to be dimensioned, constructed and arranged for supporting and releasably clamping the template apparatus onto upper portions or upper end regions or faces or upper wall portions of a plurality of the already installed piles, especially 2 or 3 or 4 or 5 or 6 or possibly even more than 6 of the already installed piles.

For the purpose of providing the releasable anchoring functionality, the clamp frame and/or other component(s) forming the supporting arrangement may include one or more clamping devices, optionally a plurality of clamping devices located on opposite lateral sides of the clamp frame, the or each clamping device being constructed and arranged for: (i) selectively clamping the clamp frame in its supported position on the already installed pile(s) so as to be anchored relative thereto whilst the next pile positioning and installation procedure is carried out, and (ii) selectively unclamping the clamp frame from its anchored position on and relative to the already installed pile(s) so as to be moveable relative thereto under the operation of the transportation means when the apparatus is to be moved into a new pile installation location.

Any suitable clamping device(s) may be used for the above purpose, examples of which are well-known in the engineering art. Moreover the manner and sequence of actuation and operation of the clamping device(s) may be incorporated in the overall control system with which the overall template apparatus is to be used and operated in the piling operation.

In some embodiment arrangements the clamping device(s) may for example be constructed and arranged to engage directly an upper wall, face, lip or end portion of the or each already installed pile which is to support the apparatus. Alternatively or additionally, the clamping device(s) may for example be constructed and arranged to engage, or interengage with, an intermediate anchoring element, member or device pre-installed or pre-anchored or preattached on the upper end of the or each already installed pile which is to support the apparatus.

For the purpose of permitting the clamp frame to be moveable relative to the already installed pile(s) once it has been unclamped from its anchored position thereon when the apparatus is to be moved into a new pile installation position, in some embodiments the clamp frame may be mounted or carried in or on the main frame of the apparatus in a longitudinally moveable, especially a longitudinally slidable, manner relative to the main frame. In such embodiments it may also be that the clamp frame is mounted or carried in or on the main frame so as to be constrained to move with the main frame when the main frame moves in a generally substantially vertical direction as the apparatus is prepared to be transported by the transportation means, as is discussed further hereinbelow. Any suitable sliding or mechanical bearing arrangement may be used to mount or carry the clamp frame in or on the main frame in the above sliding manner. The clamp frame may be moveable relative to the main frame as or when required under the action of drive means, e.g. a motor, which is operably connected to the clamp frame and/or to the main frame in order to drive the clamp frame in its sliding direction relative to the main frame as and when needed. Further constructional and functioning details of particular embodiment clamp frame arrangements will be discussed in further detail further hereinbelow in the context of some specifically described example embodiments of the invention as shown in the accompanying drawings.

In many practical embodiments of the apparatus of the present invention the transportation means may also be provided or located also at least in a median region or portion of the apparatus, and/or possibly at least in part in a rearward facing or extending (i.e. towards an end distal from the end at which is provided the engagement means) region or portion of the apparatus. In some such embodiments the transportation means may also be provided in a major proportion of the apparatus which is other than that region or portion thereof that comprises the engagement means. Moreover, in some practical embodiment arrangements the transportation means and the support means may have at least one or more, optionally some, components in common, e.g. depending on their respective precise physical and mechanical constructions and arrangements.

In some embodiments of the present invention the transportation means of the template apparatus may comprise drive means, e.g. a motor, operably connected to the template apparatus, especially to a main frame thereof, and drivable to cause the apparatus to move from its first or an existing installation position relative to the already installed pile(s) on which it is supported into its second or a successive new installation position relative to those pile(s), in which second installation position the apparatus defines the next, new installation location of the next pile to be installed in the array or series.

To enable such movement of the template apparatus, in some embodiments the transportation means may include one or more first complementary components of one or more running devices, and one or more second complementary components of the running devices(s) may be provided, either pre-installed or temporarily mounted on, an upper end or end portion of one or more of the already installed pile(s) on which the apparatus is supported and relative to which it is to be moveable. Such one or more running devices, whose various complementary components may in such embodiments be provided on either or both of the main frame of the template apparatus and/or the piles themselves, may comprise for example one or more elongate tracks or channels or racks or other running-facilitating members, in cooperation or engagement with which run (as the apparatus moves) one or more, optionally a series of a plurality of, wheels or rollers or other rolling or running members.

In some alternative embodiments, again in order to enable such movement of the template apparatus relative to the already installed pile(s), instead of the second complementary components of the one or more running devices being provided on the already installed pile(s) it/themselves, the second complementary components of the one or more running devices may instead be provided on the clamp frame of the apparatus, which clamp frame is itself supported on and anchorable to the already installed piles as discussed above. Thus, in such alternative embodiments, once the clamp frame has been clampingly anchored to the already installed pile(s), the main frame may be moveable relative to the anchored clamp frame via the one or more running devices. In this manner the main frame of the apparatus may be drivably moved in its forward transported direction relative to both the already installed pile(s) and the clamp frame once the latter has been anchored thereto.

The drive means of the transportation means may act on one or more of the complementary components of the one or more running devices, especially for example one or more of the wheels or rollers or other rolling or running members, to effect the movement of the main frame of the apparatus relative to the piles. The actuation and running speed of the drive means may be governed and controlled by the overall control system with which the overall template apparatus is to be used in the piling operation.

In practical embodiments of the invention the movement of the main frame of the apparatus relative to the already installed pile(s) from one installation position to the next, under the action of the transportation means, may in general terms be carried out whilst the apparatus remains supported on the said already installed pile(s). However, it will be appreciated that in some embodiments, in particular where a clamp frame is employed to so support the apparatus on the already installed pile(s) while the main frame (with the pile engagement device carried on a forward end thereof) is transported to its next, new installation position, once that new installation position has been reached the clamp frame then needs to be slidingly moved and repositioned relative to the main frame into a new, forwardly advanced position in which it supports the apparatus on a new group of one or more already installed piles, especially including the immediately preceding installed pile, so that that new, forwardly advanced position of the clamp frame now becomes the new “first installation position” of the apparatus.

For this purpose, in some embodiments the template apparatus may further include - either as part of the support means or as part of the transportation means, or as part of both - a lifting mechanism operatively mounted on or to the main frame for selectively and temporarily taking over the supporting (and optionally also clamping) function of the clamp frame on the already installed pile(s) whilst the clamp frame is slidably moved relative to the main frame (now supported via the lifting mechanism) into a new, forwardly displaced supporting (and optionally clamping) position relative to a different, further forwardly defined, group of one or more of the already installed pile(s).

In some such embodiments the lifting mechanism may be constructed and arranged for moving, especially by movement in a generally vertical direction or a direction generally parallel to the longitudinal axes of the piles, the main frame between: (i) a first, or lowered, position relative to the already installed pile(s) in which: (a) the main frame of the apparatus is supported on the already installed pile(s) via the (optionally clamped) clamp frame, and (b) the main frame is free to move forwardly, relative to the clamp frame (i.e. and relative to the already installed pile(s)) and e.g. by means of the above-mentioned one or more running devices, from an existing or its “first” installation position to a next, new or “second” installation position forwardly displaced relative to the “first” installation position; and (ii) a second, or raised, position relative to the already installed pile(s) in which: (c) the main frame of the apparatus is supported on the already installed pile(s) via one or more support elements of the lifting mechanism, and (d) the clamp frame is free to slidingly move relative to the main frame into a new, forwardly displaced supporting (and optionally clamping) position relative to a different, further forwardly defined, group of one or more of the already installed pile(s).

In some such embodiments the lifting mechanism may comprise a stamp frame, as referred to above. The stamp frame may be carried on or within the main frame and be moveable relative thereto, such as under the action of additional drive means, e.g. one or more additional motors or additional hydraulic devices, substantially only in a vertical direction or a direction generally parallel to the longitudinal axes of the piles. Thus, the stamp frame may be mounted on or in the main frame so as to be constrained to move with the main frame in the longitudinal direction of travel of the apparatus when the drive means of the transportation means acts on it.

In some such embodiment arrangements the stamp frame may comprise one or more feet which are constructed and arranged for abutting or bearing against one or more of the already installed pile(s) as and when the stamp frame temporarily assumes or takes over the main frame-supporting function from the clamp frame. Owing to the ability of the stamp frame to be drivably moved relative to the main frame, once the foot/feet of the stamp frame has/have been placed in their abutting or bearing position against the relevant already installed pile(s), driving of the clamp frame relative to the main frame thus moves the main frame relative to the stamp frame. Depending on the direction of drive of the drive means, either upward raising or downward lowering movement of the main frame - and thus all the other components of the apparatus attached to or integrally incorporated within it - between its above-defined raised and lowered positions may be effected. Further constructional and functioning details of particular embodiment lifting mechanism arrangements will be discussed in further detail further hereinbelow in the context of some specifically described example embodiments of the invention as shown in the accompanying drawings.

In practising embodiments of the present invention, the initial one or more, e.g. 1 or 2 or 3 or 4 or 5 or 6, or possibly more than 6, already installed pile(s) which are the very first one(s) in the array or series to be installed and provide the initial means of support for the template apparatus during its initial stage of the piling operation may itself/themselves be installed by any suitable means, either by use of a conventional pile insertion apparatus or technique or by use of the template apparatus of the present invention itself. In the latter case, however, the template apparatus may be used in a more conventional sense, and for example simply mounted on a support location or site on a platform or vessel located alongside or adjacent the initial piling site, rather than on a pile, and from there used to install the first one or few (e.g. 1 or 2 or 3 or 4 or 5 or 6, or possibly more than 6) piles until a sufficient number of initial piles have been installed to support the template apparatus stably actually thereon and enable it to be used as discussed above in its characteristic new and inventive manner.

In practising embodiment piling operations within the scope of the present invention, such as in the building of a combi-wall or other marine structure, once the requisite main, especially tubular or cylindrical, piles have been installed in the required array or series using the template apparatus of the invention, the structure may be completed as necessary by the insertion between the installed main piles of an appropriate number and configuration of sheet piles, such as infilling generally flat, e.g. sheet steel, sheet piles, using conventional techniques and equipment and in a known manner. As is already practised in the art, to facilitate the stable and secure construction of the final structure, suitable inter-engageable attachment, securement, locking and/or sealing devices or formations may be provided, especially preformed, on respective sides or edges of the main and the infilling sheet piles, and which may be e.g. welded together, so that once the sheet piles have been inserted between the main piles and so e.g. welded in place, a stable, secure and watertight combi-wall or other structure can be created.

Within the scope of this application it is envisaged and explicitly intended that the various aspects, embodiments, features, examples and alternatives, and in particular any of the variously defined and described individual features thereof, set out in any of the preceding paragraphs, in the claims and/or in any part of the following description and/or accompanying drawings, may be taken and implemented independently or in any combination. For example, features described in connection with one particular embodiment or aspect are to be considered as applicable to and utilisable in all embodiments of all aspects, unless expressly stated otherwise or such features are, in such combinations, incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the present invention in its various aspects will now be described, by way of schematic and illustrative examples only, with reference to the accompanying drawings, in which: FIGURE 1 is a large-scale plan perspective view of a typical marine setting in which a piling operation employing an embodiment template apparatus of the invention is in the process of being carried out; FIGURE 2 is a perspective view of a template apparatus according to an embodiment of the invention in position supported atop a group of already installed piles and having just completed installation of one next pile in the array or series; FIGURE 3 is a more detailed perspective view of the embodiment template apparatus alone, showing its various main functional component parts; FIGURE 4 is a somewhat simplified perspective view of the embodiment template apparatus of FIGS. 2 and 3, showing more clearly the general arrangement of its main functional component parts; FIGURE 5 is a perspective view of the embodiment template apparatus showing in particular the main frame component thereof (including the pile engagement device), including the main frame component shown separately for greater clarity; FIGURES 6(a), 6(b), 6(c) and 6(d) are, respectively, perspective, top plan, side and end views of the main frame component of FIG. 5; FIGURE 6(e) is another perspective view of the main frame component of the apparatus as shown in FIG. 5, but viewed from the opposite end and showing some of its additional components in greater detail; FIGURE 6(f) is a perspective view of a trunnion box as used in the main frame component shown in FIG. 6(e); FIGURE 7 is a perspective view of the embodiment template apparatus showing in particular, including separately for greater clarity, the clutch guides used therein; FIGURE 8 is a perspective view of one of the clutch guides shown in FIG. 7; FIGURE 9 is a perspective view of the embodiment template apparatus showing in particular, including separately for greater clarity, the roller boxes used therein; FIGURES 10(a), 10(b), 10(c), 10(d) and 10(e) are, respectively, perspective, sectional (1 only), top plan - retracted, top plan - advanced, and perspective (1 only) of the roller box devices shown in FIG. 9; FIGURE 11 is a perspective view of the embodiment template apparatus showing in particular the stamp frame component thereof, including the stamp frame component shown separately for greater clarity; FIGURES 12(a), 12(b), 12(c) and 12(d) are, respectively, perspective, top plan, side and end views of the stamp frame component of FIG. 11; FIGURE 13 is a perspective view of the embodiment template apparatus showing in particular the clamp frame component thereof, including the clamp frame component shown separately for greater clarity; FIGURES 14(a), 14(b), 14(c) and 14(d) are, respectively, perspective, top plan, side and end views of the clamp frame component of FIG. 13; FIGURE 15 is a perspective view of the clamp frame component of FIG. 13 showing in clearer detail its side beams; and FIGURE 16 is a schematic plan view of a portion of an example of a complete built combi-wall structure, comprising the main piles installed using the embodiment template apparatus and infilled with respective infilling sheet piles.

DETAILED DESCRIPTION OF EMBODIMENTS FIG. 1 illustrates a typical marine setting in which a piling operation is in the process of being carried out using a template apparatus according to an embodiment of the invention. The marine setting is a harbourside setting, where a combi-wall is being built in the sea S a short distance offshore to form a new harbour wall, which in this illustrated example extends in a substantially straight line, although in other examples could be curved, depending on requirements. The initial stages of the piling operation involve the installation of an array or series of tubular steel piles 60, which are shown being inserted into the seabed in a generally straight line sequence, moving in a forward direction F as each next pile is installed. The positioning and orientation of each new pile 60 is defined and controlled by the template apparatus 100 of the invention embodiment, which is supported atop a few, e.g. 3, 4 or 5 (depending on the overall scale of the operation), of the previously installed piles. Once each new pile has had its correct position and orientation defined and controlled by the template apparatus and the new pile has been installed, the template apparatus is driven to ride atop and along the already installed piles to assume the next pile installation position ready for the next new pile. Thus, as the series of piles is installed the template apparatus rides atop and along the already installed piles in an incremental stepwise manner, without needing to be removed from or dismantled inbetween defining each new piling installation location.

For the actual insertion of each pile 60 into the seabed whilst being supported and accurately positioned and oriented by the template apparatus 100, a pneumatic vibro-hammer device and/or an impact hammer device may be used, as are already known in the art of piling, these and other components of the overall set-up being supported, supplied and controlled from a floating marine platform or vessel 10 located alongside or adjacent the piling site, thereby forming a general operating base for the piling operation. Also located on the platform or vessel 10 is a crane 16 used to lift piles 30 into position read for installation. FIG. 2 shows the template apparatus 100 in detail, and is shown here having just completed the installation of a next new pile 60N in the series, whilst being supported on 4 of the previously installed piles 60P. It is to be understood that the number of already installed piles on which the template apparatus 100 may be supported may vary, depending for example on the dimensions of the template apparatus, the spacings of the already installed piles 60P, and the overall scale and weight of the set-up. FIG. 2 also shows, labelled as “X”, “Y” and “Z” the three orthogonal axial directions in which the template apparatus 100 is able to control and adjust the overall position and orientation of a pile 60N placed within it and supported thereby during its insertion by the vibro-hammer and/or impact-hammer device(s).

In general terms the template apparatus comprises the following principal components or sections: a main frame 120, which provides the main structure of the overall apparatus and carries or contains the other main components and operative sections; an engagement device 140 at the forward end of the apparatus, for defining the installation location of the next new pile 60N to be installed and supporting and controlling its position and orientation during its insertion; a clamp frame 160, for supporting and selectively anchoring the template apparatus 100 on the already installed piles 60P and providing part of the transportation means by which the apparatus 100 is transportable from one pile installation location to the next; and a stamp frame 160, being part of a lifting mechanism which enables the apparatus to be positioned in a transportable mode, as and when its moving to a new forwardly displaced pile installation location is required. FIGS. 3 and 4(a) - (d) show these various principal components or sections of the template apparatus 100 in further detail, including their inter-relationship in the overall constructional arrangement of the template apparatus 100. FIGS. 5 and 6(a) - (e) show in particular the main frame 120 of the apparatus in greater detail. Generally speaking the main frame 120 comprises a framework of interconnected steel frame members, which together creates and provided a strong, rigid and sufficiently stable frame to house, carry and support the various functional components of the template apparatus 100 when in use or operation, whilst enabling the overall apparatus 100 to be transported atop the various piles 60 in a stable manner as or when required to do so and also when it is required to be lifted onto or lifted off the piles at the beginning or the end of the piling operation. FIG. 6(e) also shows, in addition to the main frame 120 itself in some further detail, the position of various padeyes 127 which are used to lift the template apparatus onto and off the piles at the start and end of the piling operation. FIG. 6(e) also shows the location of a trunnion box 122 (which is shown in further detail in FIG. 6(f)) which houses a hydraulic piston-in-cylinder device (possibly one of a plurality of such devices for the same purpose) that serves to further control and/or adjust the overall position or orientation of the apparatus 100 in the X axial direction, if or as or when required. FIG. 7 shows the clutch guides 240 that are located in the forward section of the main frame 120 of the apparatus 100, where the pile engagement device 140 is located, and FIG. 8 shows the constructional arrangement of one of the clutch guides 240in further detail. FIGS. 9 and 10(a) - (e) show in various visual representations the three-dimensionally arranged pile engagement device 140 which forms the means by each new pile 60N to be installed is supported and its position and orientation controlled during its insertion by the vibro-hammer device. As shown, two groups each of 4 equi-angularly disposed and equi-spaced hydraulic piston-in-cylinder devices 144 are provided, mounted on appropriate frame members, each group being spaced from the other in the Z axial direction. The devices of the upper group are labelled 144U and those of the lower group are labelled 144L. Carried (e.g. via mounting pins 147 - FIG. 10(e)) at the radially inner end of each piston 148 (which piston 148 is shown by way of example in the cross-section of FIG. 10(b)) of each respective device 144 in each group is a respective dual-roller rolling element 142, those rolling elements being labelled likewise as 142U (those of the upper group) and 142L (those of the lower group). Each of the rolling elements 142U, 142L is designed for abuttingly bearing and rolling against an outer wall or surface of a pile 60N as it is inserted in the seabed through the framework of the engagement device 140 by the vibro-hammer device.

As shown in FIGS. 10(c) and 10(d), each hydraulic piston-in-cylinder devices 144 is selectively and independently retractable and advanceable, so as to permit the precise three-dimensional spatial position and orientation of the pile 60N being installed to be accurately and assuredly defined, controlled and maintained in each and all of the X, Y and Z axial directions during its insertion operation. In the context of many embodiment of piling operations in accordance with the present invention this is likely to be important, because since one or more previously installed piles are being used to support the template apparatus 100 whilst the next pile’s installation position and/or orientation is defined by the engagement device 140, any error or tolerance in the position or orientation of any one individual pile is desirably not compounded or accumulated in the positioning and orienting of a next pile 60N whose position and/or orientation may be dependent on or defined by or with reference to that of the previous pile 60P.

When it comes to transporting the template apparatus 100 from one pile installation location to the next, it is caused to move in a linear path across the already installed piles 60P whilst remaining supported thereon. The main frame 120 is carried on the already installed piles 60P and selectively clampingly anchorable relative thereto, especially while a given pile 60N is installed. This is achieved using a clamp frame 160, whose constructional arrangement is shown in FIGS. 13, 14(a) - (d) and 15. The clamp frame comprises side beams 166 (FIG. 15) carried on respective elongate side arms or members 162A, 162B. Mounted on each of the side arms or members 162A, 162B are a pair of longitudinally spaced apart additional hydraulic piston-in-cylinder devices that serve to further control and/or adjust the overall position or orientation of the apparatus 100 in the Y axial direction, if or as or when required.

To provide the releasable anchoring functionality, the clamp frame 160 (or possibly alternatively the main frame 120) includes an arrangement of hydraulically operated clamps 166, each clamp 166 being arranged to selectively clamp the clamp frame 160 onto a respective upper end of a respective already installed pile 60P in the clamp frame 160’s supported position thereon so as to be anchored relative thereto whilst the next pile positioning and installation procedure is carried out, and selectively unclamping the clamp frame 160 from its anchored position on and relative to the already installed piles 60P so as to be moveable relative thereto under the operation of the driven transportation means when the apparatus 100 is to be moved into a new pile installation location.

To permit the clamp frame 160 to be moveable relative to the already installed piles 60P once it has been unclamped from its anchored position thereon when the apparatus 100 is to be moved into a new pile installation position, the clamp frame 160 is mounted in the main frame 120 in a longitudinally slidable manner relative to the main frame 1120. At the same time, the clamp frame 160 is mounted in the main frame 120 so as to be constrained to move with the main frame 120 when the latter moves in the Z axial direction as the apparatus 100 is prepared to be transported to a next pile installation location. Any suitable sliding or mechanical bearing arrangement may be used to mount or carry the clamp frame 160 in the main frame 120 in this sliding manner. The clamp frame 160 can be moved relative to the main frame 120 as or when required under the action of a drive motor (not shown), which is operably connected to the clamp frame 160 and/or to the main frame 120 in order to drive the clamp frame 160 in its sliding direction relative to the main frame 120 as and when needed.

For driving the template apparatus from its first or an existing installation position, relative to the already installed piles 60P on which it is supported, into its second or a successive new installation position relative to those piles 60P, as and when required, a suitable motor (not shown) operably connected to the main frame 120 causes the apparatus 100 to move from its first to its second such positions, so that once the apparatus 100 reaches that second position relative to those piles 60P it defines the next, new installation location of the next pile 60N to be installed in the array or series. The actuation and running speed of the drive motor may be governed and controlled by the overall control system with which the overall template apparatus is to be used in the piling operation.

To enable such movement of the apparatus 100 there are provided appropriate cooperating and/or complementary components of one or more running devices (not shown), e.g. in the form of rollers or wheels running in a running track. First such complementary components of the one or more running devices are mounted on the main frame 120, and second such complementary components of the one or more running devices may be either pre-installed or temporarily mounted on an upper end or end portion of one or more of the already installed piles 60P on which the apparatus 100 is supported and relative to which it is to be moveable, or alternatively mounted on the clamp frame 160 itself.

Since the clamp frame 160 is employed to support the apparatus 100 on the already installed piles 60P while the main frame 120 (with the pile engagement device 140 carried on a forward end thereof) is transported to its next, new installation position, once that new installation position has been reached the clamp frame 160 then needs to be slidingly moved and repositioned relative to the main frame 120 into a new, forwardly advanced position in which it supports the apparatus 100 on a new group of one or more already installed piles 60P, especially including the immediately preceding installed pile 60N, so that that new, forwardly advanced position of the clamp frame 160 now becomes the new “first installation position” of the apparatus 100.

For this purpose, a lifting mechanism comprising stamp frame 180 is provided, being operatively mounted in the main frame 120 for selectively and temporarily taking over the supporting (and optionally also clamping) function of the clamp frame 160 on the already installed piles 60P whilst the clamp frame 160 is slidably moved relative to the main frame 120 (now supported via the stamp frame 180) into a new, forwardly displaced supporting (and optionally clamping) position relative to a different, further forwardly defined, group of one or more of the already installed piles 60P. The constructional arrangement of the stamp frame 180 is shown in FIGS. 11 and 12(a) - (d).

The stamp frame 180 comprises feet 182, being forward foot 182F and rearward foot 182R. The forward foot 182F is carried by a pair of forward legs 188 and the rearward foot 182R is carried by two pairs of rearward legs 186R and 186F. The stamp frame 180 is mounted and carried within the main frame 120 in such a way that it is moveable relative thereto in the Z axial direction, yet is not moveable relative thereto in the X or the Y axial directions. Thus, the stamp frame 180 is mounted in the main frame 120 such that is able to move, only in the Z axial direction, the main frame 120 relative to itself between: (i) a first, or lowered, position relative to the already installed piles 60P in which: (a) the main frame 120 is supported on the already installed piles 60P via the (optionally clamped) clamp frame 160, and (b) the main frame 120 is free to move forwardly, relative to the clamp frame 160 (i.e. and relative to the already installed piles 60P) and by means of the above-mentioned one or more running devices, from an existing or its “first” installation position to a next, new or “second” installation position forwardly displaced relative to the “first” installation position; and (ii) a second, or raised, position relative to the already installed piles 60P in which: (c) the main frame 120 is supported on the already installed piles 60P via one or more of the feet and legs 182F, 182R, 186F, 186R, 188 of the stamp frame 180 itself, and (d) the clamp frame 160 is free to slidingly move relative to the main frame 120 into a new, forwardly displaced supporting (and optionally clamping) position relative to a different, further forwardly defined, group of one or more of the already installed piles 60P.

The stamp frame 180 is mounted within the main frame 120 so as and be moveable relative thereto in the Z axial direction under the action of additional drive motors or hydraulic devices 126, optionally with appropriate gearing arrangements. At the same time, however, the stamp frame 180 is mounted in the main frame 120 so as to be constrained to move with the main frame 120 in the longitudinal direction of travel F of the apparatus 100 when the drive means of the transportation means acts on it.

Thus, feet 182R, 182F of the stamp frame 180 are arranged for abutting or bearing against one or more of the already installed piles 60P as and when the stamp frame 180 temporarily assumes or takes over the main frame 120-supporting function from the clamp frame 160. Owing to the ability of the stamp frame 180 to be drivably moved relative to the main frame 120, once the feet 182R, 182F of the stamp frame 180 have been placed in their abutting or bearing position against the relevant already installed piles 60P, driving of the clamp frame 160 relative to the main frame 120 thus moves the main frame 120 relative to the stamp frame 180. Depending on the direction of drive of the drive motor, either upward raising or downward lowering movement of the main frame 120 - and thus all the other components of the apparatus 100 attached to or integrally incorporated within it - between its above-defined raised and lowered positions can be effected.

In the overall piling operation, the initial few (e.g. 4) piles 60P that are installed for the purpose of providing the initial support base for the template apparatus 100 as the piling operation progresses may themselves be installed by temporarily using the template apparatus 100 in an equivalent manner to a convention piling template structure, for example simply mounted on a support location or site on the platform or vessel 10, rather than on a pile, and from there used to install the first 4 piles, that being in this example a sufficient number of initially installed piles for supporting the template apparatus 100 stably thereon and enable it to be used as discussed above in its characteristic new and inventive manner.

Once the main piling operation has been completed and the array or series of piles 60 installed, the template apparatus can simply be lifted off and away from the piling site and the remaining stages of the combi-wall building operation completed, especially in a conventional manner. This will normally include the insertion, inbetween the installed piles 60, of the requisite number of infilling generally flat, e.g. sheet steel, sheet piles 360 (FIG. 16), using conventional techniques and equipment and in a known manner. A schematic example of part of a complete combi-wall arrangement is shown in FIG. 16. To facilitate the stable and secure construction of the final combi-wall structure, suitable inter-engageable attachment, securement, locking and/or sealing devices or formations 400 may be provided, especially preformed, on respective sides or edges of the main 60 and the infilling 360 sheet piles, and which may be e.g. welded together, so that once the sheet piles 360 have been inserted between the main piles 60 and so welded in place, a stable, secure and watertight combi-wall or other structure is created.

In using the template apparatus 100 of embodiments of the invention in embodiment methods of piling also within the scope of the invention, at least some of the various principal procedural actions and considerations that may be employed and practised, which have been defined and generally described hereinabove, may be further particularised - by way of non-limiting example only - as follows: (A) Summary of Piling Work Method

The piles of the combi-walls will be installed with the two-layered piling template. First all tubular piles will be installed. The sheet-pile infills will be placed afterwards, independently of the piling template. A.1 Positioning of piling template

The piling template will be supported on top of the already installed piles. To assure correct positioning of the next pile, the position of the piling template must be adjustable (in transversal, longitudinal, pile verticality and pile orientation directions).

First rough positioning of the template will be done based on the position of the previously installed piles. To avoid an accumulating error, the absolute position of the piling template will be measured by means of a total station, such that final adjustments of pile verticality and pile position can be made.

The piling template will be relocated and positioned during upending of the next pile. The template will be positioned as accurately as possible, before the pile is brought in the template. A.2 Bring pile in pile template

As soon as the piling template is brought in position and the verticality of the template is assured, the next pile can be brought in the piling template. The piles will be inserted in the piling template from the top. During lowering, only one layer will be engaged, to avoid large overturning moments in the piling template due to potential side lead in the crane. The second layer will be engaged just before touchdown of the pile on the soil. A.3 Assure pile position and verticality

Just after touchdown, position and verticality of the pile will have to be confirmed by measurement from the total station. In case horizontal positioning is incorrect, the pile will be lifted again and repositioned. In case the verticality is incorrect, the inclination will be adjusted by the top rollers. A.4 Pitch pile

The pile is pitched before the placement of the vibro-hammer. As soon as the pile is pitched, the vibro-hammer will be placed on top and the pile will be vibrated. Before changing the vibro-hammer for an impact hammer, the verticality and position of the pile should be confirmed. If out of tolerance, the pile should be pulled out and pitched again. A.5 Drive pile

The hammer should pass the template during driving, which means that the rollers should be retractable. (B) Detailed Description of Piling Work Method B.1 Install the template on the piles (i) Check combi-wall piles: - Check if piles are installed within tolerances for inclination; - Check if piles are installed within tolerances for top level height; - Check if piles are installed within tolerances for alignment; - Check if sufficient piles are installed to support the gate at its clamping positions. (ii) Preparation: - Read the operational manual; - Check if piling template is assembled correctly for the diameter and CTC distance of the tubular piles to install; - Check if stoppers welded at the correct position on the bottom of the stamp frame; - Check if no equipment or loose parts within range of the template are obstructing the functionality of the structures; - Check if the piling clamps are secured on the correct position which matches the pile diameter; - Check if the piling clamps are maximal opened; - Check if the roller boxes to be fully retracted; - Check if the clamp frame is centered transversally and the Y-cylinder presses against the main frame. - Check if the clamp frame is supported by the most forward guiding beams; - Check if stamp frame is fully retracted; - Check if power pack is ready for use; - Check if no loose elements are on the gate when lifting; - Verify all people on the frame are located within pre-defined “operating areas” - only crew that are required for visual checking can be close to the equipment during operation. - NOTE: If any faults are found during inspection, abort/postpone operation to replace/repair compromised parts. (iii) Lift the template on the installed piles: - Attach rigging to the assigned padeyes, verifying that there is sufficient clearance between the rigging and HPU; - Lift the template, verifying that the gate is level when lifted; - Position the template above the piles, verifying that the clamp mouths are positioned above the pile walls; - Lower further until the pile wall is inserted in the clamp mouth for all four clamps, verifying the correct position of all four clamps - Engage all four piling clamps; - Once installation complete, verify that all four clamps are engaged, and permit to Load Form to be completed. B.2 Transfer load from clamp frame to stamp frame (i) Preparation: - Before operating the stamp frame, the following items require inspection: - Verify that the piling clamps are engaged; - Verify that the safety clamps © are NOT engaged; - Verify that the clamps are positioned accurately above the pile edges; - Verify that there are no loose items on the frame; - Verify all people on the frame are located within pre-defined “operating areas” - only crew that are required for visual checking can be close to the equipment during operation. - Verify no objects obstruct the movements of the frame; - NOTE: If any faults are found during inspection, abort/postpone operation to replace/repair compromised parts. (ii) Transfer load from clamp frame to stamp frame: - Operate the X- and Y-cylinders to position the template until the top of the pile is located between the markings on the stamps (noting that the markings indicate the position of the stopper blocks which are welded below the stamps); - Verify the top of the pile is located between the markings (stopper blocks) which are welded below the stamps; - If not already there, add markings on the top of the stamp to indicate the correct position for future use; - Operate the Z-cylinders to lower stamp frame further until it touches the pile - the load of the template will be transferred from the clamp frame to the stamp frame by lowering the stamp frame further until the clearance between the clamp frame and the sliding pads shifts from the bottom to the top; - Verify the clearance between clamp frame and sliding pads at all 10 positions is located at the top of the clamp frame. - Attach the stamp frame to the pile using the safety clamps. B.3 Level the piling template (i) Preparation: - Before levelling the piling template, the following items require inspection: - Verify that the clamp frame fully supports the piling template; - Verify that the safety clamps are engaged; - Verify that there are no loose items on the frame; - Verify all people on the frame are located within pre-defined “operating areas” - only crew that are required for visual checking can be close to the equipment during operation; - Verify no objects obstruct the movements of the frame. - NOTE: If any of the checks are not positive, abort/postpone operation, solve the problem and perform the above-mentioned checks again. (ii) Level the piling template: - Disengage the piling clamps, verifying that the piling clamps are fully disengaged; - Operate the Z-cylinders to level the piling template; - During levelling of the frame: visually inspect the spirit level, and immediately stop the operation if the frame inclination exceeds 2 degrees around the X-axis; - After levelling of the frame: use the spirit level to verify that the frame is level. B.4 Transfer load from stamp frame to clamp frame (i) Preparation: - Before operating the stamp frame, the following items require inspection: - Verify that the piling clamps are fully opened; - Verify that the safety clamps are engaged; - Verify that clamps are accurately positioned above the pile edges; - Verify that there are no loose items on the frame; - Verify all people on the frame are located within pre-defined “operating areas” - only crew that are required for visual checking can be close to the equipment during operation; - Verify no objects obstruct the movements of the frame. - NOTE: If any of the checks are not positive, abort/postpone operation, solve the problem and perform the above-mentioned checks again. (ii) Transfer load from stamp frame to clamp frame: - Operate the Z-cylinders to retract the stamp frame into the main frame until the pile wall is inserted in the piling clamp mouth (min. 200 mm); - N.B. Immediately stop operation when piling clamp lands on the pile wall; - Verify the minimum insertion of 200 mm for all four piling clamps; - Engage the piling clamps, verifying that all four piling clamps are fully engaged; - Operate the Z-cylinders to retract the stamp frame further into the main frame - the load of the template will be transferred from the stamp frame to the clamp frame, and the clearance between the clamp frame and the sliding pads on the base/lower corners of the frame will shift from the top to the bottom of the clamp frame; - Verify the clearance between clamp frame and sliding pads at all 10 positions is located at the bottom of the clamp frame. B.5 Manoeuvre the template to next piling position (i) Preparation: - Before operating the stamp frame, the following items require inspection: - Verify that the piling clamps are engaged; - Verify that the safety clamps are NOT engaged; - Verify the last installed pile is level with previously installed piles; - Verify the hammer is removed from the pile; - Verify that there are no loose items on the frame; - Verify no objects obstruct the movements of the frame; - Verify all people on the frame are located within pre-defined “operating areas” - only crew that are required for visual checking can be close to the equipment during operation; - NOTE: If any of the checks are not positive, abort/postpone operation, solve the problem and perform the above-mentioned checks again. (ii) Skid main frame: - Operate the Y-cylinders to release pressure from the main frame; - Operate the X-cylinder to roughly manoeuvre the piling template to the next piling position; - N.B. Pay attention to pinching of piling clamps’ hydraulic hoses when the X-cylinder is operated to maximum stroke! - N.B. Pay attention to clashes and pinching of piling clamps’ hydraulic hoses when the X-cylinder is operated over 50mm outside of the CTC nominal pile distance! (iii) Retract clamp frame: - Transfer load from clamp frame to stamp frame (see section B.2 above); - Verify the height between the piles and the clamps is sufficient to skid the clamps over the edge of the piles; - Operate the X-cylinder to retract the clamp frame; - Repeat the steps of sections B.3 and B.4 above; - N.B. Pay attention to pinching of piling clamps’ hydraulic hoses when the X-cylinder is operated to maximum stroke! - N.B. Pay attention to clashes and pinching of piling clamps’ hydraulic hoses when the X-cylinder is operated over 50mm outside of the CTC nominal pile distance! (iv) Fine-tune the template to piling position: - Operate the X- cylinder and Y-cylinders to fine-tune the piling template to piling position; - N.B. Pay attention to pinching of piling clamps’ hydraulic hoses when the X-cylinder is operated to maximum stroke! - N.B. Pay attention to clashes and pinching of piling clamps’ hydraulic hoses when the X-cylinder is operated over 50mm outside of the CTC nominal pile distance! - N.B. Pay attention to clashes when the rod of the Y-rear cylinders sticks more than 360 - 500 mm outside the cylinder housing. - When the template is in piling position, make secure all Y-cylinders press against the main frame to secure the clamp frame position; - Verify the accuracy of the final piling position; - Use the spirit level to verify that the frame is still level; - When the template is not level, repeat the steps of sections chapter B.2 to B.4 above to level the template. B.6 Loading piles and piling (i) Preparation: - Before operating the stamp frame, the following items require inspection: - Verify that the piling clamps are engaged; - Verify that the clutch guides are vertically aligned and retracted; - Verify that the rollerboxes are all retracted; - Verify all Y-cylinders press against the main frame to secure the clamp frame; - Verify that the piles are brought to the site as assumed in the design report; - Verify that the environmental conditions are as assumed in the design report; - Verify all people on the frame are located within pre-defined “operating areas” - only crew that are required for visual checking can be close to the equipment during operation; - NOTE: If any of the checks are not positive, abort/postpone operation, solve the problem and perform the above-mentioned checks again. (ii) Pile loading: - Lower the pile between the rollerboxes in the template; - Use the rollerbox cylinders to engage the bottom level rollerboxes after the pile has passed the bottom rollerbox level - rollerboxes to be engaged with a loose grip; - Continue lowering the pile and stop just before it touches the seabed; - Extend the clutch guides and shim them with the provided clutches; - Tighten the clutch guides wing bolts to maintain the position; - Use the rollerbox cylinders to engage the top level rollerboxes - the rollerboxes to be engaged with a loose grip; - Continue lowering until the pile touches the seabed. (iii) Piling: - Lift hammer on the pile; - Hammer pile and stop when the hammer is just above the top level rollerboxes; - Retract the top level rollerboxes to pass through the hammer; - Retract the clutch guides; - Hammer pile and stop when the hammer is just above the lower level rollerboxes; - Retract the lower level rollerboxes to pass through the hammer; - Hammer pile further until the top of the pile is level with the previous piles; - Retrieve hammer. (iv) Move to next piling position: - Restart the procedure from paragraph B.5(ii).

It is to be understood that the above description of various specific embodiments of the invention in its various aspects has been by way of non-limiting examples only, and various modifications may be made from what has been specifically described and illustrated whilst remaining within the scope of the invention as defined by the appended claims.

Throughout the description and claims of this specification, the words “comprise” and “contain” and linguistic variations of those words, for example “comprising” and “comprises”, mean “including but not limited to”, and are not intended to (and do not) exclude other moieties, additives, components, integers or steps.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

Claims

1. A piling template apparatus for defining a pile installation location in a piling operation, the template apparatus comprising: engagement means constructed and arranged for engaging and supporting a pile to be installed at the said pile installation location; support means constructed and arranged for supporting the template apparatus on one or more other piles already installed in the piling operation; and transportation means constructed and arranged for transporting the template apparatus relative to one or more of said other piles.

2. A piling template apparatus according to claim 1, which is for positioning and/or supporting a pile to be installed in a piling operation, the said pile being a next pile of an array or series of a plurality of piles being installed in the piling operation, wherein the template apparatus comprises: the said engagement means for engaging and supporting the said next pile in a desired location and/or orientation in which it is to be installed, and the said support means for supporting the template apparatus on one or more other piles of the array or series already installed in the piling operation; wherein the template apparatus includes the said transportation means for transporting the template apparatus from a first installation position in which it is supported on one or more already installed piles of the array or series and at a location defining an installation location of a previously installed pile, to a second installation position in which it is supported on one or more already installed piles of the array or series and in which it defines an installation location for the said next pile to be installed in the array or series.

3. A piling template apparatus according to claim 1 or claim 2, wherein the piling operation is a sequential piling operation, in which a plurality of piles are installed one after another in a linear sequence or row and the template apparatus is constructed and arranged so as to be transportable from one pile installation position or location to the next pile installation position or location in a sequential, staged, stepwise or incremental manner, wherein each stage or step or increment of the transportational movement of the apparatus takes place between individual installation operations of respective individual piles as the overall piling operation progresses.

4. A piling template apparatus according to claim 2 or claim 3, wherein the transportation means is constructed and arranged for transporting the template apparatus from the first installation position to the second installation position in a translational manner.

5. A piling template apparatus according to any preceding claim, wherein the apparatus comprises a main frame constructed and arranged for housing and/or carrying and/or supporting at least some of the components of at least one or more of the engagement means, the support means and the transportation means.

6. A piling template apparatus according to any preceding claim, wherein the apparatus comprises, independently of a main frame, a clamp frame constructed and arranged to provide and/or carry and/or support at least some of the components of at least one or more of the support means and the transportation means.

7. A piling template apparatus according to any preceding claim, wherein the apparatus comprises, independently of any main frame and/or any clamp frame, a stamp frame constructed and arranged to provide and/or carry and/or support at least some other components of at least one or more of the support means and the transportation means.

8. A piling template apparatus according to any preceding claim, wherein the engagement means is provided or located at a forward end of the apparatus, that forward end being an end of the apparatus in the direction of which the apparatus is designed to travel under operation of the transportation means in moving it from one pile installation position or location to the next.

9. A piling template apparatus according to any preceding claim, wherein the engagement means comprises an engagement device including: one or more engagement members constructed and arranged for engaging and supporting a pile placed in the device; and one or more adjustment devices each constructed and arranged for acting on the or a respective one of the engagement members for adjusting or modifying the position and/or orientation of the said pile placed in the device relative to the remainder of the apparatus.

10. A piling template apparatus according to claim 9, wherein the engagement device includes a plurality of the said engagement members, with each said engagement member being provided with a respective associated one of a plurality of the said adjustment devices.

11. A piling template apparatus according to claim 9 or claim 10, wherein: (i) the or each engagement member comprises a roller or other bearing member or element which is arranged to abuttingly engage an outer wall or surface of a pile that is placed in the device in order to be positioned and supported thereby, and/or (ii) the or each adjustment device comprises a piston-in-cylinder device constructed and arranged for controlling and/or adjusting and/or altering to any extent necessary the position, relative to the or the respective pile, of the or the respective one of the engagement members.

12. A piling template apparatus according to any one of claims 9 to 11, wherein a plurality of groups each of two or more engagement members and associated adjustment devices are provided in the engagement device of the apparatus, wherein each group is spaced apart from the other(s) in a generally substantially vertical direction (or a direction parallel to the general longitudinal length axes of the piles).

13. A piling template apparatus according to any preceding claim, wherein the support means comprises a supporting arrangement comprising one or more support members or support devices which are constructed and arranged for supporting the template apparatus on the one or more other piles of the array or series previously installed in the piling operation, optionally wherein, in addition to their supporting function, the one or more support members or support devices are constructed and arranged for releasably anchoring the template apparatus on the one or more already installed piles.

14. A piling template apparatus according to any preceding claim, as dependent through claim 6, wherein the supporting arrangement comprises the said clamp frame.

15. A piling template apparatus according to claim 14, wherein the one or more support members or support devices are constructed and arranged for releasably anchoring the template apparatus on the one or more already installed piles, and the clamp frame and/or other component(s) forming the supporting arrangement includes one or more clamping devices, the or each clamping device being constructed and arranged for: (i) selectively clamping the clamp frame in its supported position on the already installed pile(s) so as to be anchored relative thereto whilst the next pile positioning and installation procedure is carried out, and (ii) selectively unclamping the clamp frame from its anchored position on and relative to the already installed pile(s) so as to be moveable relative thereto under the operation of the transportation means when the apparatus is to be moved into a new pile installation location.

16. A piling template apparatus according to claim 14 or claim 15, as dependent through claim 5, wherein the clamp frame is mounted or carried in or on the main frame of the apparatus in a longitudinally moveable, optionally a longitudinally slidable, manner relative to the main frame, whereby the clamp frame is moveable relative to the already installed pile(s) once it has been unclamped from its anchored position thereon when the apparatus is to be moved into a new pile installation position.

17. A piling template apparatus according to claim 16, wherein the clamp frame is moveable relative to the main frame as or when required under the action of drive means.

18. A piling template apparatus according to any preceding claim, wherein the transportation means comprises drive means operably connected to the template apparatus and drivable to cause the apparatus to move from its first or an existing installation position relative to the already installed pile(s) on which it is supported into its second or a successive new installation position relative to those pile(s), in which second installation position the apparatus defines the next, new installation location of the next pile to be installed in the array or series.

19. A piling template apparatus according to claim 18, wherein the transportation means include one or more first complementary components of one or more running devices, and one or more second complementary components of the running devices(s) are provided: (i) either pre-installed or temporarily mounted on an upper end or end portion of one or more of the already installed pile(s) on which the apparatus is supported and relative to which it is to be moveable; or (ii) on the clamp frame of the apparatus, the clamp frame being itself supported on and anchorable to the already installed piles, whereby once the clamp frame has been clampingly anchored to the already installed pile(s), the main frame is moveable relative to the anchored clamp frame via the one or more running devices.

20. A piling template apparatus according to any preceding claim as dependent through claims 5 and 6, wherein the apparatus further includes a lifting mechanism operatively mounted on or to the main frame for selectively and temporarily taking over the supporting (and optionally also clamping) function of the clamp frame on the already installed pile(s) whilst the clamp frame is slidably moved relative to the main frame (now supported via the lifting mechanism) into a new, forwardly displaced supporting (and optionally clamping) position relative to a different, further forwardly defined, group of one or more of the already installed piles.

21. A piling template apparatus according to claim 20, wherein the lifting mechanism is constructed and arranged for moving, optionally by movement in a generally vertical direction or a direction generally parallel to the longitudinal axes of the piles, the main frame between: (i) a first, or lowered, position relative to the already installed pile(s) in which: (a) the main frame of the apparatus is supported on the already installed pile(s) via the (optionally clamped) clamp frame, and (b) the main frame is free to move forwardly, relative to the clamp frame (i.e. and relative to the already installed pile(s)) from an existing or first installation position to a next, new or second installation position forwardly displaced relative to the first installation position; and (ii) a second, or raised, position relative to the already installed pile(s) in which: (c) the main frame of the apparatus is supported on the already installed pile(s) via one or more support elements of the lifting mechanism, and (d) the clamp frame is free to slidingly move relative to the main frame into a new, forwardly displaced supporting (and optionally clamping) position relative to a different, further forwardly defined, group of one or more of the already installed piles.

22. A piling template apparatus according to claim 20 or claim 21, as dependent through claim 7, wherein the lifting mechanism comprises the said stamp frame.

23. A piling template apparatus according to claim 22, as dependent further through claim 5, wherein the stamp frame is carried on or within the main frame and is moveable relative thereto substantially only in a vertical direction or a direction generally parallel to the longitudinal axes of the piles, whereby the stamp frame is mounted on or in the main frame so as to be constrained to move with the main frame in the longitudinal direction of travel of the apparatus when the drive means of the transportation means acts on it.

24. A piling template apparatus according to claim 22 or claim 23, wherein the stamp frame comprises one or more feet which are constructed and arranged for abutting or bearing against one or more of the already installed pile(s) as and when the stamp frame temporarily assumes or takes over the main frame-supporting function from the clamp frame.

25. A piling template apparatus according to any preceding claim, wherein the apparatus further includes one or more auxiliary adjustment devices constructed and arranged for acting on one or more of a main frame, a clamp frame or a stamp frame of the apparatus for auxiliarily adjusting or modifying the position and/or orientation of the apparatus relative to the already installed pile(s) prior to or during the installation of a pile.

26. A method of positioning and/or supporting a pile before and/or during installation thereof in a piling operation, the said pile being a next pile of an array or series of a plurality of piles being installed in the piling operation, the method comprising: providing a piling template apparatus according to any one of claims 1 to 25, the template apparatus being positioned in a first installation position in which it is supported on one or more already installed piles of the array or series and at a location defining an installation location of a previously installed pile; operating the transportation means so as to transport the template apparatus from the said first installation position into a second installation position in which it is supported on one or more already installed piles of the array or series and in which it defines an installation location for the said next pile to be installed in the array or series; and inserting the said next pile into the engagement means of the apparatus and actuating the engagement means so as to engage and support the said next pile in the said desired location and/or orientation in which it is to be installed.

27. A method of piling, in which a plurality of piles are installed in an array or series thereof, the method comprising: (i) providing a piling template apparatus according to any one of claims 1 to 25, and positioning the template apparatus in a first installation position in which it is supported on one or more already installed piles of the array or series and defines a first installation location for a first new pile of the array or series; (ii) actuating the engagement means so as to engage and support the said first new pile at the said first installation location and/or in a desired orientation in which it is to be installed at that first installation location; (iii) installing the said first new pile; (iv) operating the transportation means of the template apparatus so as to transport the template apparatus from the said first installation position into a second installation position in which it is supported on one or more already installed piles of the array or series including the said installed first new pile and in which it defines a second installation location for a second new pile to be installed of the array or series; (v) inserting the said second new pile into the engagement means of the apparatus and actuating the engagement means so as to engage and support the said second new pile at the said second installation location and/or in a desired orientation in which it is to be installed at that second installation location; and (vi) installing the said second new pile.

28. A method of piling according to claim 27, wherein steps corresponding to (iv), (v) and (vi) are repeated as many times as may be necessary with respect to any number of new piles that may be desired in the installation of the total number of piles in the overall piling operation.

29. An array or series of piles installed using the template apparatus according to any one of claims 1 to 25, or installed according to the method of piling according to claim 27 or claim 28.

30. A structure incorporating piles installed using the template apparatus according to any one of claims 1 to 25, or installed according to the method of piling according to claim 27 or claim 28.

31. A structure according to claim 30 which is a marine combi-wall.