Patent Application
20250067040
The present application relates to a method of construction, and more particularly to a method for the formation of structural wall elements that are constructed of fluid structural materials that set or harden within a unique formwork system.
Hydraulic concrete is the most commonly used construction material in the world. This material is highly versatility and can be engineered for a wide variety of desired structural parameters. The economics of horizontal concrete slabs-on-grade is very different than vertical walls and elevated slabs due to the effects of gravity. For vertical walls, the labor costs for fabricating, transporting and placing reinforcing steel and fabricating, erecting and stabilizing formwork prior to concrete placement is a substantial portion of the overall construction cost. Formwork costs are substantial enough that sets of formwork are often reused or rolled between wall segments to maximize their value. The purpose of the formwork is to rigidly contain the fluid hydraulic concrete until it sets sufficiently to sustain the vertical and shear loads internally.
All of the preparation effort prior to and after concrete placement adds a significant amount of cost to the built product that often prices this method of construction out the residential and light commercial industries. In addition to material and labor costs, the current methods of forming and casting vertical concrete structures adds a significant amount of time to the overall construction process.
This disclosure focuses on a general method of casting solid wall sections of a particular shape that eliminates many of the inherent costs in the current standard practices. It is desired that a system and method be provided to simplify and lessen the costs of such building methods. The term concrete is used herein to describe fluid structural materials that harden into rigid structural elements.
It is an object of the present application to provide a concrete air form structural forming system and method for the construction of upright structures using fluid concrete. The system and method includes the use of a vinyl, inflatable air form to support a particular shape of the fluid concrete. The structural forming system creates walls with a curved geometry so that rigid formwork is not required on the upper side of the wall. Formwork, falsework or permanent structure can be used for the lower, supporting side of the wall. An impermeable membrane form made of vinyl sheet or any other similarly performing material that is inflated and anchored on top of the lower form is used to contain the fluid concrete product and remains in place after the material hardens.
It is a further object of the present application that the system and method be scalable to allow for structures of any size to be constructed. Additionally, an object of the present application is to provide a system that utilizes considerably less time to construct, at least partially accomplishing this purpose by allowing for at least one side of the inflatable air form to be unsupported with formwork.
Ultimately the invention may take many embodiments. In these ways, the present invention overcomes the disadvantages inherent in the prior art. The more important features have thus been outlined in order that the more detailed description that follows may be better understood and to ensure that the present contribution to the art is appreciated. Additional features will be described hereinafter and will form the subject matter of the claims that follow.
Many objects of the present application will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
Before explaining at least one embodiment of the present invention in detail, it is to be understood that the embodiments are not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The embodiments are capable of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the various purposes of the present design. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present application.
The novel features believed characteristic of the application are set forth in the appended claims. However, the application itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
While the embodiments and method of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the application to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the process of the present application as defined by the appended claims.
Illustrative embodiments of the preferred embodiment are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the embodiments described herein may be oriented in any desired direction.
The embodiments and method in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with the prior art discussed previously. In particular, a new method to construct concrete structures is provided that greatly reduces the overall cost and time required by current practices. Vertical concrete walls require rigid formwork on each side with header or plug formwork on each end of the planned placement (unless abutting a previously placed section). By canting or tilting a wall a specific amount it is possible to eliminate one side of the formwork.
Due to the hydraulic nature of concrete even a highly engineered product would not perform as desired with a significant enough vertical angle to actually form a structural wall. This has been accomplished with a specific type of structural element using several unique features. Using a continuously curved wall section that tapers toward a ridge or peak provides the proper wall geometry. This geometry is best suited for dome and barrel-vaulted structures. While the lower or inward supporting structure could be falsework that is removed after placement, it could also be permanent structure that remains in place after the concrete wall cures.
An element that may contain the hydraulic concrete in place while curing is a vinyl form that is fabricated to the proper dimensions for the structural element. Vinyl air-form structures can be ordered in a wide variety of customizable shapes and sizes and are generally inflated with low-pressure air pumps. Air fill ports can be installed during the fabrication of each segment shape that can also be used as concrete injection ports. These membranes provide little rigidity and are only intended to contain the fluid concrete within the desired shape while curing and then remain in place as an exterior barrier or integral skin to the concrete member.
This structural forming system eliminates the need to procure materials, construct and deconstruct at least the outer formwork for a structural wall. If the inner wall support system is designed to be a permanent part of the final structure there is no material or labor waste with temporary formwork. In addition, using a highly designed “concrete” mix with the addition of structural filaments in the mix the material, labor and time associated with this step in a normal wall construction are eliminated. These and other unique features are discussed below and illustrated in the accompanying drawings.
The embodiments and method will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the assembly may be presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless otherwise described.
The embodiments and method of the present application is illustrated in the associated drawings. The concrete air form structure of the present application includes a bass track configured to support a frame having a plurality of ribs extending vertically therefrom. The plurality of ribs combine adjacent a singular elevated point in the dome application or at commonly spaced points in the vault/barrel application above the base track. The frame includes a frame support spanning between the plurality of ribs used to support a lower surface of an inflatable concrete form. The concrete form is configured to inflate and be filled selectively filled with fluid concrete. The frame structure is configured to provide a lower support to the fluid concrete within the air form so as to provide a desired shape. The upper shape of the concrete air form is dictated by the inflatable concrete form. Additional features and functions are illustrated and discussed below.
Referring now to the Figures wherein like reference characters identify corresponding or similar elements in form and function throughout the several views. The following Figures describe embodiments of the present application and its associated features. With reference now to the Figures, embodiments of the present application are herein described. It should be noted that the articles “a”, “an”, and “the”, as used in this specification, include plural referents unless the content clearly dictates otherwise.
Referring now to
The Dome structure shown in figures one through 4 and in corresponding other figures is constructed using system 101. Use of the system and method described herein reduces the amount of forms typically used when forming fluid concrete. An inflatable air form is used to provide the shape and contour of the concrete structure on at least one exposed face without support from formwork. Fluid concrete is filled within the air form. The air form is then retained around the concrete when dried.
System 101 includes a foundation 103, a base track 105, a support assembly 107, a frame 109, and an inflatable air form 111. Base track 105 is configured to rest upon the foundation surface. Foundation 103 is configured to encompass the area of base track 105 and to fill the internal area. It is understood that foundation 103 is optional, partially dependent upon the intended use of the overall structure. System 101 may include a solid or partially open foundation 103. Foundation 103 may be made from any material and may be used as much or as little as necessary for the intended purpose of the overall structure. It is understood that the size of system 101 may be set to include any diameter.
Frame 109 is configured to include one or more components illustrated later in the drawings. Frame 109 is coupled to base track 105 at a first end and is elevated distally from base track 105 at a second end. Frame 109 is configured to provide the overall shape of the intended structure. Frame 109 is also configured to support portions of the concrete walls.
As seen from the Figures, air form 111 is configured to rest on the base track 105 in between portions of frame 109. Air form 111 is a hollow flexible member having a predefined shape. Air form 111 is configured to contact portions of frame 109 along a lower surface, such that frame 109 provides support along the lower surface of air form 111. Air form 111 may be formed from various different materials such as vinyl, and maybe considered to be a membrane that separates the concrete from frame 109.
An advantage of system 101 is the usage of air form 111. Where typically fluid concrete structural walls would need to be supported with formwork on all sides, air form 111 is configured to serve as the formwork along at least one surface without additional external support. Ideally this surface is an upper outer surface wherein the predetermined form or shape of air form 111 is configured to restrict and define the overall outer external surface of the fluid concrete when set. Air form 111 is configured to surround the concrete and remain as such even after drying. Using system 101, frame 109 along with base track 105 and air form 111 provide the necessary structural support for the formation of the concrete wall. Little to no external form work is required. Additionally, system 101 may remain in place after the drying of the concrete, thereby saving time and expense removing external formwork as seen with existing methods.
Referring now also to
Frame 109 may optionally include a support assembly 107. Assembly 107 is configured to support the second end of the frame 109 in an elevated position. Assembly 107 may be configured to include a column or post 113 that extends downward from the second end to foundation 103. It is understood that the overall frame structure and its corresponding shape may negate the need for assembly 107. For example, as seen in the case with a dome shape, the second end of frame 109 may be configured to couple together in a closed configuration at the peak of the dome. In such a configuration it is conceivable that assembly 107 is not necessary, however, use of assembly 107 is not only feasible but may be recommended depending on the size and curvature of the overall structural body.
Assembly 107 may include a collar 115 either coupled 2 or formed along and end of post 113. Collar 115 is configured to provide support for the second end of frame 109. Frame 109 will rest upon and upper surface of collar 115 hand or coupled to a side surface of collar 115. It is understood that collar 115 may be configured to translate a long post 113 in some embodiments.
As seen in particular with
Referring now also to
Frame 109 includes a plurality of ribs as seen in
Referring now also to
Referring now also to
To reiterate, an advantage of using air form 111 is the ability to remove extra steps from creating form work to define the shape of the concrete. Additionally, usage of air form 111 allows a user or operator to have a variety of shapes available that would be difficult or unrealistic to mold out of typical wooden frames. Furthermore, air form 111 is configured to remain surrounding the concrete thereby eliminating extra steps for dismantling formwork.
Air form 111 is configured to include one or more ports for the insertion of air and/or fluid concrete. Concrete is inserted into air form 111 typically from a lower portion to a higher portion. A port 123 is included at an upper end of air form 111 to permit the introduction of air into the hollow interior of the air form. The insertion of air acts to fully shapen and expand air form 111. In this expanded shape air form 111 permits the introduction of fluid concrete through one or more auxiliary ports 125. While air is being introduced through port 123, and operator may simultaneously introduce fluid concrete through any of auxiliary ports 125. It is naturally assumed that systematic progression from a lower auxiliary port to a higher auxiliary port is preferred as air form 111 is filled with fluid concrete.
In operation of system 101, an operator sets track 105 at a desired location. Frame 109 is erected with ribs 119 being elevated sequentially. Rows of ribs 119 are selectively secured to track 105. An operator locates supports 121 along an upper surface of flange 120. Supports 121 extend between opposing internal surfaces of ribs 119. Supports 121 act as a lower support for air form 111. Assembly 107 may be inserted when necessary so as to locate and secure the second end of frame 109. Air form 111 is located a long and upper surface of supports 121 between ribs 119. Air is forced into the interior of air form 111 so as to expand its shape. Once expanded and operator may use auxiliary ports 125 to insert concrete. The insertion of forced air and fluid concrete may be done simultaneously. The forced air helps to ensure fluid concrete reaches the full interior of air form 111. When air form 111 is full of fluid concrete all axillary ports and port 123 are closed and the concrete is permitted to set. When the concrete is fully set frame 109 and air form 111 may be retained around the concrete thereby eliminating the need to remove form work. It is understood that one or more openings or holes may be included in air form 111 so as to permit windows or doorway openings for example. It is also worth noting that system 101 is scalable to any size or shape.
Referring now also to
The membrane form (air form) of the structural forming system 101/201 can be filled with specifically engineered Portland Cement concrete mixtures, Geopolymer Cement mixtures, mortar mixtures or Ultra-lightweight concrete mixtures (ULC, Foamcrete, Aircrete, etc.); all generally referred to as “concrete” in this application. The type of “concrete” used in this structural forming system determines the weight of each wall segment, the strength requirements of the supporting structure or interior wall and supports, the curing properties, the size and number of required placement lifts and the depth of the wall segment. The interior wall design must be customized based on the selection of the “concrete” material and properties.
The structural forming system of the present application does not allow the use of reinforcing bars embedded within the “concrete” matrix. A variety of products currently available, such as Carbon Nanotubes (CNT), metal filaments and plastic filaments have been considered to replace standard rebar for crack control and structural stiffening.
The particular embodiments disclosed above are illustrative only, as the application may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. It is apparent that an application with significant advantages has been described and illustrated. Although the present application is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof.
