The present disclosure relates to a building system and method for constructing a structure having a plurality of vertical sidewalls.
Systems and methods utilized for forming structures fail to provide flexible means for constructing walls or structures in a module manner having adequate vertical and horizontal support throughout the entire construction process in addition to having the capacity to install materials such as pouring concrete in an efficient manner. Systems and methods utilized for forming structures also fail to provide modular building systems that are easy to assemble prior to forming a structure and easy to disassemble after the structure has formed.
A complete understanding of the present embodiments and the advantages and features thereof will be more readily understood by reference to the following detailed description, appended claims, and accompanying drawings, wherein:
The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
Reference will now be made in detail to the exemplary embodiment(s), examples of which is/are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
Before describing the exemplary embodiments, it is noted the embodiments reside primarily in combinations of components and procedures related to the apparatus. Accordingly, the apparatus components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
The specific details of the various embodiments described herein are used for demonstration purposes only, and no unnecessary limitation or inferences are to be understood therefrom. Furthermore, as used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship, or order between such entities or elements.
In general, a building system as disclosed herein may include a wall assembly including a plurality of expanded metal mesh sheets disposed on either side of at least one welded wire mesh sheet. The wall assembly may be disposed in a keyway defined by a foundation assembly including a plurality of form boards. The foundation assembly may be constructed and arranged for framing out a slab. the building system may further include a framing assembly including a plurality of vertical supports spaced away from one another and being constructed and arranged to connect to a support header and plurality of spans such that a structure or wall may be formed within the framing assembly.
In practice and use, a method for using the building system may include installing a plurality of form boards and attaching a keyboard to the form boards. The method may further include assembling vertical supports outside of the to-be-constructed wall or structure and installing at least one span between adjacent vertical supports and support headers. A plurality of straps including j-hooks may be disposed within each of the spans and may be constructed and arranged to receive horizontal braces within the j-hook. According to some embodiments, at least one welded wire mesh may also be suspended from the straps. The method may further include affixing horizontal braces to vertical braces prior to forming at least one slab or pouring a wall material such as concrete between a first metal mesh sheet and a second metal mesh sheet to form a wall or structure.
As shown in
In some embodiments, the wall assembly 102 comprises at least one expanded metal mesh sheets 104 and at least one welded wire mesh sheets 106. In some embodiments, the wall assembly 102 comprises a plurality (e.g., two, three, etc.) of expanded metal mesh sheets 104a, 104b, and a welded wire mesh sheet 106 sandwiched between the two expanded metal mesh sheets 104a, 104b. In some embodiments, the welded wire mesh sheet 106 and each of the expanded metal mesh sheets 104a, 104b are positioned a spaced distance from one another as best seen in
In some embodiments, the wall assembly 102 comprises at least one horizonal supports 108. In such embodiments, the supports 108 are positioned laterally between adjacent vertical supports 302. The supports 108 can be any suitable material, including, for example, steel rebar. The supports 108 are sized and shaped to lay on a j-hook portion of at least one vertical strap 110 projecting downward from a span 306, as best seen in
In some embodiments, the foundation assembly 200 comprises a plurality of form boards 202 for framing out a slab C1. The form boards 202 can be any suitable material, including, e.g., wood, metal, polymer or a composite material. In some embodiments, the form boards 202 are positioned horizontally with the width of the board having one face in the direction of the interior side of the to-be-constructed wall and the opposite face of the board in the direction of the exterior side of the to-be-constructed wall. The slab C1 can be any suitable material for a building foundation, including, for example, stone, wood, concrete, etc.
The form boards 202 can be any suitable size, including, for example, 1″×12″; 1″×10″; 1.5″×12″; 1.5″×10″; 2″×12″; or 2″×10″; or 4″×12″ or 4″×10″; etc. (height×width in inches). All dimensions are interchangeable and/or combinable. The size of the form board 202 is selected based on the desired size of the wall and building structure to be constructed, the local or regional code of building regulations, the terrain where the structure will lay, and/or the preferences of the builder.
In some embodiments, the foundation assembly 200 comprises at least one keyboards 204. In some embodiments, the top surface of the keyboards 204 is flush with the top surface of the form boards 202. In some embodiments, the keyboards 204 are removable; and, when the keyboards 204 are removed, a keyway is provided in the slab C1. In some embodiments, the keyboards 204 are fastened from the external side 101b of the form boards 202. The fastener can be any suitable fastener (e.g., screw, nail), and may be removable from the external side 101b.
The keyboards 204 can be any suitable size, including, for example, 1″×4″; or 1″×3″; or 1″×2.75″; or 1″×2″; or 1″×1.5″; or 1.5″×4″; or 1.5″×3″; or 1.5″×2.75″; or 1.5″×1.5″; or 2″×4″; 2″×3″; 2″×2.75″; or 2.75″×1.5″; or 2.75″×2″ or 2.75″×2.5″; etc. (height×width in inches). All dimensions are interchangeable and/or combinable. The size of the keyboard 204 is selected based on the desired size of the keyway, the local or regional code of building regulations, and/or the preferences of the builder.
In some embodiments, the framing assembly 300, or components thereof, is/are removeable and reusable. In some embodiments, the framing assembly 300 comprises a plurality of vertical supports 302. The supports 302 are structured to be vertically disposed in an underlying surface, in spaced apart relation from one another, and appropriately secured in place. The supports 302 can be any suitable material, including, for example, steel rebar. In this context, a suitable material means the supports 302 are strong enough to hold up an arrangement of support headers 304, spans 306, and associated components without bending. In other words, the supports 302 should maintain a linear or substantially linear shape throughout the process. In some embodiments, the keyboards 204 are adapted to receive the vertical supports 302. For example, a notch 205 can be cut out or otherwise be displaced from the keyboard 204 in the appropriate size and shape to securely receive the support 302. The supports 302 can be any suitable length (i.e., to accommodate a suitable height from the surface of the ground). In some embodiments, the supports 302 are structured to be one inch, or 2″, or 3″, or 4″, etc., from the desired wall height.
In some embodiments, the framing assembly 300 comprises at least one support headers 304. In particular, a support header 304 is structured to be removably disposed on an exposed end of each of the supports 302 that have been previously anchored in the underlying surface (e.g., ground). In some embodiments, each of the support headers 304 includes a mounting hub that removably engages (e.g., a tubular opening that receives) the exposed end of the supports 302, such that after construction of a wall section and/or the entire structure, the support header 304 can be removed from its engaged relation with the supports 302 and reused at a subsequent location. In some embodiments, support headers 304 are structured to receive and removably engage and retain a span 306. In some embodiments, a plurality of spans 306 are provided, each span structured to extend between adjacent supports 302 and their corresponding support headers 304. Additional elements are contemplated for achieving effective and appropriate aligned positioning of the spans 306 between the adjacent supports 302, but also allowing for appropriate removability of the support headers 304 and spans 306 for subsequent reuse.
In some embodiments, the framing assembly 300 comprises at least one vertical braces 308. In such embodiments, the braces 308a can be included on the interior side of the to-be-constructed wall and the braces 308b can be included on the exterior side of the to-be-constructed wall. The vertical braces 308a, 308b can be any suitable material, including, for example, wood (e.g., 2′×4′) (height×width). In some embodiments, the upper end of a plurality of vertical braces 308 is removably coupled to the span 306. For example, in some embodiments, an upper portion of the vertical braces 308 are coupled to the span 306 using a horizontal strap 312 projecting out from the span 306. In some embodiments, the span 306 comprises at least one slots 313 configured to receive the strap 312. In some embodiments, the span 306 comprises a slot 313a on the interior side of the span 306 and a slot 313b on the exterior side of the span. In such embodiments, the slots 313a, 313b are arranged on the opposing faces of the span 306 so the strap 312 can pass entirely through the span 306. In such embodiments, the straps 312 can be coupled to the interior vertical braces 308a and the exterior vertical braces 308b. In some embodiments, a plurality of interior vertical braces 308a are arranged at a lower end on the slab C1. In some embodiments, a plurality of exterior braces 308b are arranged at a lower end on the ground.
In some embodiments, the framing assembly 300 comprises at least one horizontal braces 310. In such embodiments, the braces 310a can be included on the interior side of the to-be-constructed wall and/or the braces 310b can be included on the exterior side of the to-be-constructed wall. The horizontal braces 310a, 310b can be any suitable material, including, for example, wood (e.g., 2′×4′) (height×width), dowl, steel rod, plastic rod, etc. In some embodiments, a plurality of interior horizontal braces 310a are removably coupled to at least one components of the wall assembly 102. For example, in
In some embodiments, the arrangement and connectivity of the vertical braces 308 and the horizontal braces 310 is configured to maintain the integrity of the desired shape and thickness of the to-be-constructed wall, as dictated in some embodiments by the spacing between the interior expanded metal mesh sheets 104a and the exterior expanded metal mesh sheets 104b (the spaced distance including the welded wire mesh sheet 106 therebetween).
In various embodiments, a method for constructing a building structure, including a plurality of sidewalls, is provided. In some embodiments, the method comprises installing the form boards 202 about ¾″ (0.75″) outside of the desired dimensions (e.g., perimeter) of the to-be-constructed walls. Next, a keyboard 204 sized about 2.75″×1.5″ (width×height in inches) is attached on the interior side of the form boards 202. In such embodiments, the form board 202 is lying vertical on its side and the keyboard 204 is laid flat so its top surface is flush with the top of the form board 202. The keyboard 204 is sized and shaped to form a keyway in the concrete slab when removed. In some embodiments, the keyboards 204 are attached from the outside surface of the form board 202 with a fastener (e.g., screw, nail) that can be removed later. In some embodiments, the top surface of the form board 202 and the top surface of the keyboard 204 are marked to indicate where the vertical support 302 will be positioned. A notch 205 in the keyboard is then cut out in an appropriate size and shape for accepting the vertical support 302. In some embodiments, supports 302 are installed in all corners and/or locations where a support is needed for the support headers 304. The supports 302 are anchored below the desired footer, and the top of the support 302 is about 2″ above the desired wall height. In some embodiments, when installed, the bottom surface of the spans 306 will be about 3″ higher than the wall after construction. In some embodiments, the about 3″ gap between the bottom surface of the span 306 and the top of the wall above will provide a sufficient gap for pouring in wall material (e.g., pumping concrete in).
In some embodiments, once the vertical supports 302 are stable, the slab steel is placed with the slab mesh extending up the wall approximately 18″ to form a starter steel for the wall. In some embodiments, the starter steel is beneficial, but in some instances is optional. In such embodiments, the vertical supports 302, the support headers 304, and spans 306 would be installed before the slab C1 is formed.
Once the supports 302, support headers 304, and spans 306 are installed, the vertical straps 110 are installed with the j-hook facing the interior side of the to-be-constructed wall. Next, the welded wire mesh 106 is suspended from vertical straps 110. In some embodiments, the bottom of the welded wire mesh 106 extends into the footer and supports the footer support bars, and then slab steel is installed. In some embodiments, horizontal braces 108 are installed one in the vertical straps 110. In some embodiments, the slab C1 is then formed, and the keyboards 204 are removed.
In some embodiments, with the keyboards 204 removed, the exterior expanded metal mesh sheets 104a, 104b is inserted in the keyway 114, and optionally coupled to the form board 202, which is still in place. The top surface of the expanded metal mesh sheets 104b should be about 3″ below the spans 306 designating the height of the finished wall. In some embodiments, the bottom surface of the interior expanded metal mesh sheets 104a rest on the slab C1 and braced by a removable wood board (e.g., 2″×4″) attached to the slab C1. The top portion of the interior expanded metal mesh sheets 104a is supported by an arrangement of at least one vertical braces 308 and at least one horizontal braces 310. In such embodiments, the at least one vertical braces 308 are coupled to the span 306 using horizontal straps 312.
In some embodiments, cut outs in the structure of the system 100 are made for windows. In some embodiments, the wall material (e.g., concrete) is then pumped in between the spaced distance between the internal expanded metal mesh sheets 104a and the external expanded metal mesh sheets 104b to obtain the desired wall (e.g., C2 and C3 combined). Once the wall is formed, with the top of the wall meeting the top of the expanded metal mesh sheets 104, the spans 306, support headers 304, supports 302, and form boards 204 can be removed, and the walls are ready to receive roofing trusses, which will be attached to the vertical straps 110.
The following description of variants is only illustrative of components, elements, acts, products, and methods considered to be within the scope of the invention and are not in any way intended to limit such scope by what is specifically disclosed or not expressly set forth. The components, elements, acts, products, and methods as described herein may be combined and rearranged other than as expressly described herein and are still considered to be within the scope of the invention.
Variation 1 may include a building system for forming at least one to-be-constructed structure, including a wall assembly including a plurality of expanded metal mesh sheets and at least one welded wire mesh sheet; a foundation assembly including a plurality of form boards for framing out a slab and at least one keyboards coupled to the form boards; and a framing assembly including a plurality of vertical supports structured to be vertically disposed on an underlying surface, the plurality of vertical supports being in a spaced apart relation from one another, each having an exposed end to removably engage with a support header, and a plurality of spans structured to extend between and be received by adjacent vertical supports.
Variation 2 may include a building system as in variation 1, wherein the wall assembly further includes a plurality of expanded metal mesh sheets and a welded wire mesh sheet disposed between the two expanded metal mesh sheets.
Variation 3 may include a building system as in any of variations 1 through 2, wherein each of the plurality of expanded metal mesh sheets are positioned a distance from one another, the distance between each of the plurality of expanded metal mesh sheets being the thickness of a to-be-constructed wall.
Variation 4 may include a building system as in any of variations 1 through 3, wherein the wall assembly further includes at least one vertical strap including a j-hook.
Variation 5 may include a building system as in any of variations 1 through 4, wherein the at least one vertical strap extends downward from at least one of the plurality of spans and wherein the j-hook is positioned towards an interior side of a to-be-constructed wall in order to receive a support.
Variation 6 may include a building system as in any of variations 1 through 5, wherein at least one of the plurality of spans defines a slot sized and shaped to receive the vertical strap therein.
Variation 7 may include a building system as in any of variations 1 through 6, wherein the span defines a plurality of slots on a downward facing surface of the span and further defines a plurality of corresponding slots on an upward facing surface of the span.
Variation 8 may include a building system as in any of variations 1 through 7, wherein the wall assembly further includes at least one vertical strap including a j-hook an defines an embedment line constructed and arranged to identify a lower portion of the strap to be disposed within a wall material during use.
Variation 9 may include a building system as in any of variations 1 through 8, wherein the wall assembly further includes at least one horizonal support positioned laterally between adjacent vertical supports constructed and arranged to seat within at least one j-hook of at least one strap.
Variation 10 may include a building system as in any of variations 1 through 9, wherein the at least one keyboards are removable and constructed and arranged to define a keyway in a to-be-constructed slab.
Variation 11 may include a building system as in any of variations 1 through 10, wherein the framing assembly includes at least one vertical brace disposed on an interior side and an exterior side of a to-be-constructed wall wherein the at least one vertical brace is removably coupled to the span.
Variation 12 may include a building system as in any of variations 1 through 11, wherein the framing assembly includes at least one exterior horizontal brace removably coupled to the exterior vertical braces.
Variation 13 may include a building system as in any of variations 1 through 12, wherein arrangement and connectivity of the at least one vertical brace and the at least one horizontal brace is configured to maintain the integrity of the desired shape and thickness of a to-be-constructed structure.
According to variation 14, a method for forming at least one to-be-constructed structure may include installing a plurality of form boards approximately outside of desired dimensions of at least one to-be-constructed wall; attaching a keyboard on an interior side of the plurality of form boards such that a top surface of the keyboard is flush with a top of at least one of the plurality of form boards, wherein the keyboard is sized and shaped to define a keyway in the at least one to-be-constructed wall; defining at least one notch in the keyboard to receive at least one vertical support; installing at least one vertical support anchored below a desired footer, the at least one vertical support being constructed and arranged to support at least one support header; installing at least one span constructed and arranged to extend between adjacent vertical supports and support headers; installing at least one vertical strap within the at least one span, the at least one vertical strap including a j-hook where in installing the at least one vertical strap includes positioning the j-hook toward an interior side of a to-be-constructed wall; suspending at least one welded wire mesh from the at least one vertical strap; installing at least one vertical brace; installing at least one horizontal brace within the j-hook; forming at least one slab; removing the at least one keyboard; installing at least one metal mesh sheet; and installing a wall material within the at least one metal mesh sheet to form the at least one to be constructed structure.
Variation 15 may include a method for forming at least one to-be-constructed structure as in variation 14, wherein installing a wall material within the at least one mesh sheet to form the at least one to-be-constructed structure includes pouring concrete.
Variation 16 may include a method for forming at least one to-be-constructed structure as in any of variations 14 through 15 wherein installing at least one metal mesh sheet further includes coupling the at least one metal mesh sheet to at least one form board.
Variation 17 may include a method for forming at least one to-be-constructed structure as in any of variations 14 through 16 wherein the at least one metal mesh sheet is supported by an arrangement of at least one vertical brace and at least one horizontal brace.
Variation 18 may include a method for forming at least one to-be-constructed structure as in any of variations 14 through 17 further including removing the plurality of spans, support headers, plurality of vertical supports, and form boards.
Variation 19 may include a method for forming at least one to-be-constructed structure as in any of variations 14 through 18 further including forming cut outs in at least one of the plurality of spans, support headers, plurality of vertical supports, at least one welded wire mesh, at least one metal mesh sheet, and form boards for windows.
According to variation 20, a method for forming at least one to-be-constructed structure may include installing a plurality of form boards approximately outside of desired dimensions of at least one to-be-constructed wall; attaching a keyboard on an interior side of the plurality of form boards such that a top surface of the keyboard is flush with a top of at least one of the plurality of form boards, wherein the keyboard is sized and shaped to define a keyway in the at least one to-be-constructed wall; defining at least one notch in the keyboard to receive at least one vertical support; installing at least one vertical support anchored below a desired footer, the at least one vertical support being constructed and arranged to support at least one support header; installing at least one span constructed and arranged to extend between adjacent vertical supports and support headers; installing at least one vertical strap within the at least one span, the at least one vertical strap including a j-hook where in installing the at least one vertical strap includes positioning the j-hook toward an interior side of a to-be-constructed wall; suspending, within the keyway, at least one welded wire mesh from the at least one vertical strap; installing at least one vertical brace; installing at least one horizontal brace within the j-hook; connecting the at least one vertical brace and the at least one horizontal brace, wherein arrangement and connectivity of the at least one vertical brace and the at least one horizontal brace is configured to maintain the integrity of the desired shape and thickness of a to-be-constructed structure; forming at least one slab; removing the at least one keyboard; installing, within the keyway, a first metal mesh sheet; installing, within the keyway, a second metal mesh sheet such that the at least one welded wire mesh is disposed between and spaced from both the first metal mesh sheet and second metal mesh sheet; and pouring concrete within the keyway and between the first metal mesh sheet and second metal mesh sheet to form the at least one to-be-constructed structure.
Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to describe and illustrate every combination and subcombination of these embodiments. Accordingly, all embodiments can be combined in any way and/or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.
An equivalent substitution of two or more elements can be made for any one of the elements in the claims below or that a single element can be substituted for two or more elements in a claim. Although elements can be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that at least one elements from a claimed combination can in some cases be excised from the combination and that the claimed combination can be directed to a subcombination or variation of a subcombination.
It will be appreciated by persons skilled in the art that the present embodiment is not limited to what has been particularly shown and described hereinabove. A variety of modifications and variations are possible in light of the above teachings without departing from the following claims.
This application claims the benefit of U.S. Provisional Application No. 63/115,166 filed Nov. 18, 2020 and which is incorporated herein by reference.
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