Conduit segment casting mold and method of forming a conduit segment

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• attaching braces between inner surfaces of the at least one inner mold;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• and
• removing the formed conduit segment from the mold base.

A conduit segment casting mold system, comprising:

• at least one inner mold;
• at least one outer mold configured as at least two outer mold sections of opposed shapes that define a cavity between the at least two outer mold sections that is sized to at least partially enclose the at least one inner mold, each of the at least two outer mold sections comprising a respective mating surface, each of the at least two outer mold sections comprising at least one hole sized to receive a cable, and the at least one hole of a particular one of the at least two outer mold sections is aligned with the at least one hole of another particular one of the at least two outer mold sections when the mating surfaces of the particular one and the another particular one of the at least two outer mold sections are mated, and each of the outer mold sections comprises a long wall and two short walls orthogonally connected to the long wall and in parallel, and the at least one hole is formed in the long wall;
• a mold base;
• and
• a cable positioned through the aligned holes and through a volume defined between the at least one inner mold and the at least one outer mold when assembled to the mold base, the volume sized to receive a volume of a hardenable material that forms at least a portion of a conduit segment, where the hardenable material, when cast, completely surrounds at least a portion of the cable positioned in the volume.

A conduit segment casting mold system, comprising:

• at least one inner mold comprising a first piston hole formed therethrough;
• at least one outer mold configured as at least two outer mold sections of opposed shapes that define a cavity between the at least two outer mold sections that is sized to at least partially enclose the at least one inner mold, each of the at least two outer mold sections comprising a respective mating surface, each of the at least two outer mold sections comprising at least one hole sized to receive a cable, and the at least one hole of a particular one of the at least two outer mold sections is aligned with the at least one hole of another particular one of the at least two outer mold sections when the mating surfaces of the particular one and the another particular one of the at least two outer mold sections are mated, the at least one outer mold comprising a second piston hole formed therethrough;
• and
• a mold base.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold, each of the at least two outer mold sections comprising a long wall and two short walls orthogonally connected to the long wall and in parallel;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• setting a rebar grid within the cavity prior to pouring the hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• and
• removing the formed conduit segment from the mold base.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• setting a rebar grid within the cavity prior to pouring the hardenable material into the cavity, where the step of setting the rebar grid is performed prior to positioning the at least one inner mold onto the mold base;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• and
• removing the formed conduit segment from the mold base.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections, where the step of positioning the at least one cable is performed prior to positioning the at least one inner mold onto the mold base;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• and
• removing the formed conduit segment from the mold base.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment, where removing the at least one outer mold comprises:
• operating one or more pistons positioned in the at least two outer mold sections to separate the at least two outer mold sections from the formed conduit segment;
• and
• detaching the respective mating surfaces of the at least two outer mold sections from contacting engagement;
• and
• removing the formed conduit segment from the mold base.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment, where removing the at least one inner mold comprises:
• operating at least one piston positioned in at least one wall of the at least one inner mold to actuate the at least one flexible hinge positioned on the at least one wall such that the at least one wall with the at least one hinge collapses inwardly away from the cast segment;
• and
• lifting the at least one inner mold up above the formed conduit segment;
• and
• removing the formed conduit segment from the mold base.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• removing the formed conduit segment from the mold base;
• forming at least one groove in an end surface of the formed conduit segment;
• and
• affixing a compressible water barrier into the at least one groove prior to use of the conduit segment.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• removing the formed conduit segment from the mold base;
• and
• inserting a compressible water barrier into a groove in the mold base, the groove shaped to receive the compressible water barrier, the water barrier protruding into the space into which the hardenable material is cast such that the hardenable material, after hardening, captures at least a portion of the compressible water barrier and where at least another portion of the water barrier protrudes out of the hardened material after being cast.

A method of forming a casting mold of a conduit segment, comprising:

• positioning at least one inner mold onto a mold base;
• positioning at least one outer mold on the mold base surrounding the at least one inner mold, the at least one outer mold configured as at least two outer mold sections that define a cavity between the at least two outer mold sections and the at least one inner mold when the outer mold surrounds the inner mold;
• positioning at least one cable in the cavity and through at least one hole formed in each of the at least two outer mold sections;
• tensioning the at least one cable to a pre-determined tension;
• subsequent to the tensioning, pouring a hardenable material into the cavity;
• curing the hardenable material poured into the cavity to form a conduit segment;
• removing the at least one inner mold and the at least one outer mold from the formed conduit segment;
• removing the formed conduit segment from the mold base;
• and
• forming a pair of grooved channels on the formed conduit segment sized to receive rails.