Patent Application
20060037278
The invention relates to walls and methods of constructing walls. More particularly, the invention relates to cast concrete walls, and even more particularly cast concrete walls including pre-cast exterior wall, and faced inner walls.
Walls have been built with and without the use of binders for hundreds of years.
Cast concrete walls are likewise known that are constructed with or without the use of reinforcing elements, such as rebar.
Concrete liquid containment vessels are known for use in the chemical, pulp, and paper industries.
There are drawbacks of the known walls and vessels.
It is an object of the invention to overcome the drawbacks of known walls and fluid containment vessels, such as liquid containment vessels.
Another object of the invention is to provide a method of constructing a wall such as in the form of a vessel, which can be erected with little or no formwork.
A further object of the invention is to provide a chemical-resistant liquid containment vessel which incorporates the economy of post-tensioned concrete with the flexibility and process adaptability of reinforced concrete.
Another object of the invention is to provide a wall in which a faced inner wall, such as an inner wall having a chemical-resistant material incorporated substantially directly into the wall, may be provided.
A still further object of the invention is to provide a method of constructing a wall, and a wall suited to post-construction changes in the wall, such by the addition of an opening in a lower portion of the wall.
A further object of the invention is to provide a wall or vessel having a chemical-resistant inner wall constructed without compromising the structural integrity of the wall or vessel.
Yet another object of the invention is to provide a method of constructing a wall, and a wall so constructed, that a chemical-resistant material for use as a face of the wall is incorporated into the wall during construction of the wall.
Another object of the invention is to ensure that a chemical-resistant material used as a face or surface of the wall remains properly bonded with the wall in use.
Yet another object of the invention is to provide a method of constructing a wall, and a wall so constructed, suitable for construction in a location having limited available space for construction formwork, such as in an existing industrial plant.
A further object of the invention is to provide a wall and method of constructing such, that is environmentally friendly, more economical to construct than known walls, and readily adapted to the demands of different construction environments and different and end-use requirements.
In summary, the method of constructing a wall according to the invention includes constructing a wall defining an upper region, a lower region, and a transition region between the upper and lower regions. The method includes erecting an exterior wall, the exterior wall including at least one layer, and the at least one layer including a wall segment having a height extending from the lower region to the transition region. The exterior wall segment may include a first material. Erecting an interior wall, the interior wall including at least one layer, the at least one layer including a wall element having a height extending within the lower region. The interior wall element may include a second material. Erecting the exterior wall at a distance from the interior wall, and providing a space between the interior and exterior walls. Providing a reinforcing element in the space between the interior and exterior walls in the lower region and providing a post-tensioning reinforcing element in the upper region of the wall. At least partially filling the space between the interior and exterior walls in the lower region of the walls with a cementitious material after the at least one layer of the interior wall has been erected.
The inventive method and wall may include that the exterior wall is erected substantially without the use formwork, and the interior wall is erected substantially without the use of formwork.
The inventive method of constructing a wall may likewise include that the interior wall defines an enclosed space.
Relative terms such as left, right, up, down, interior, exterior, cementitious, wall, and the like are for convenience only and are not intended to be limiting.
Wall 10 may include an inner wall 14 and an outer wall 18. A reinforcing wall 20 may be provided adjacent one or both of inner wall 14 and outer wall 18. A reinforcing wall 20 may be provided between both inner wall 14 and outer wall 18, and reinforcing wall 20 may be directly adjacent one or both of inner and outer walls 14 and 18, depending on the intended use.
A roof or cap 16 may be provided depending on the intended use.
A reinforcing structure 24 may be provided adjacent inner and outer walls 14 and 18, and may be between walls 14 and 18.
A cementitious material 28, such as concrete or cement, may be used in forming reinforcing wall 20.
Reinforcing structure 24 may be adjacent to, or partially or completely encased by reinforcing wall 20. Reinforcing structure 24 may include a variety of reinforcing elements, such as natural or synthetic aggregate, metal or plastic reinforcing fibers, metal reinforcing elements including rebar (reinforcing bar) typically made of steel and the like.
Wall 10 may be reinforced substantially consistently throughout its height or width or both.
Wall 10 may be substantially divided into an upper portion or region 30, a lower portion or region 40, and a middle or central region 50 disposed between the upper and lower regions 30 and 40. Central region 50 may be termed a transition region between lower region 40 and upper region 30, depending on the intended use.
Reinforcing structure 24 may differ in upper portion 30 from the configuration of reinforcing structure 24 in lower region 40. For example, one or more post-tensioned elements 60, which may include one or more cables or elongated elements 62, and one or more corresponding cable guides 64 may be provided in upper region 30.
Cable 62 may include one or more free ends 66 and 68, such as shown in
A housing 80 may be provided that is configured for receiving one or more lock-off couplers 70, free end 66 and free end 68 of cable 62.
Housing 80 may include a left wall 84 and a right wall 86, as shown in
Left wall 84 may be configured for mating with a free end 92 of an outer wall segment 90. Right wall 86 may likewise be configured for mating with a corresponding free end 94 of wall segment 90.
Wall segment 90 may be one or more wall segments 90, depending on the intended use.
Exterior wall segments 90 may be made of a material such as pre-cast concrete.
One or more lifting elements 98 may be provided in wall segment 90, so that wall segment 90 may be raised into place. Lifting elements 98 may be attached to wall segment 90 during the forming of wall segment 90, after the forming of wall segment 90, or during the erection of wall 10. The user or installer may use a piece of conventional lifting equipment for raising up and setting in place wall segment 90 during construction of the wall as will be readily appreciated.
Inner wall 14 may include one or more layers or lifts 102, 104, and 106 of bricks or tiles 112.
When erecting a first layer 102, depending on the intended use, adjacent bricks or tiles 112 may be joined together by use of a mortar or adhesive 120. Mortar 120, when used, may be of a variety of materials depending on the intended use and the type of brick or tile 112 to be joined together. Further layers or lifts 104 and 106 may likewise be joined to previously laid layers by use of mortar 120, again depending on the intended use.
After one or more layers 102 and 104, for example, have been laid, and mortar 120 has cured sufficiently, the cementitious material 28 forming reinforcing wall 20 may be provided between exterior wall 18 and interior wall 14, such as by pouring an uncured concrete 28 into the space 130 defined between interior wall 14 and exterior wall 18. The concrete 28 will be added up to a desired level, such as up to the height of an uppermost layer 106 of inner wall tiles, as shown in
The process of adding layers 102, 104, 106, and so forth of tiles 112, and mortar 120 as needed, allowing mortar 120 to cure, as needed, and making additional pours of concrete 28 will be continued to a desired height.
At least a part of one or both of exterior wall 18 and interior wall 14 may be supported by formwork placed on one or both of the inside or outside of respective exterior and interior walls 18 and 14.
In installation locations where little working space is available outside of, namely outwardly of the exterior of exterior wall 18, thanks to the configuration of wall segment 90 with its optional configured free ends 92 and 94, wall 10 may be erected without the use of exterior formwork on the outside of exterior wall 18.
Post-tensioned element 60 likewise may be used to ensure that wall segments 90, as needed, are sufficiently securely held in place during construction of wall 10, whether or not configured free ends 92 and 94 are provided, so that exterior formwork is not needed. After the desired number of layers or lifts 102, 104, 106, and so forth of tiles 112 have been laid, and after cable 62 has been sufficiently post-tensioned after a sufficiently long curing time of concrete 28, then interior 88 of housing 80 may be filled in with a cementitious material. To assist during the filling in of interior 88, bricks or tiles may be used to form or close an open face 144 of housing 80.
In the case where wall 10 is to be built as a vessel for retaining a fluid such as liquid, the user may wish to provide one or more openings in wall 10 for accessing a liquid contained therein in use.
Thanks to the use of lower reinforcing structure 170 in lower portion 40, an opening 150 may be provided during the initial construction of the interior wall 14, such as prior to the pouring of concrete 28 around a nozzle 160. Alternatively, after construction of lower portion 40, for example, hole 150 may be provided, such as by drilling through exterior wall 18, cured concrete 28, and interior wall 14. A nozzle 160 may then be inserted. Nozzle 160 may be secured in place by conventional means, or in the case where nozzle 160 is made of a weldable material, which material may be welded to lower reinforcing structure 170, nozzle 160 may be directly physically secured to lower reinforcing structure 170. Thanks to the use of horizontal and vertical rebar array 172 and 173 in lower portion 40, nozzle 160 may be installed without degrading the integrity of lower reinforcing structure 170, even if a part of lower reinforcing structure 170 is removed when forming hole 150.
If desired, the user may install one or more reinforcing elements 172 and 174, such as pieces of rebar, which may be welded together in a manner so as to restrict movement of nozzle 160 out of its desired orientation during pouring of concrete 28. Thus, one or more reinforcing elements 172, 174 may be secured to one or more portions of lower reinforcing structure 170, such as by wiring or tack welding reinforcing element 172 to lower reinforcing structure 170. A harness or array of reinforcing elements may constitute reinforcing element 172 to restrict movement of nozzle 160.
Depending on the intended use, a slab or foundation 200 may be provided on which wall 10 is erected.
One or more holes 210 may be provided in foundation 200, such holes 210 being sized to receive a lower free end of vertical reinforcing element 171, for example. A securing element, such as a dowel, may be provided between a side of hole 210 and vertical reinforcing element 171.
It will be appreciated that various components may be made of synthetic materials, including plastics, metal, including but not limited to steel, cast iron, aluminum, and other appropriate metals depending on the intended use.
Appropriate sealants for ensuring fluid-tight connections may be used at appropriate joints and interfaces between different elements of wall 10, as well as between wall 10 and its surroundings. For example, at an interface between wall 10 and foundation 200.
The bricks or tiles used as the interior wall may be chemical-resistant materials such as chemical-resistant SEMCO™ (Stebbins Engineering and Manufacturing Co., Watertown, N.Y.), or a SEMCO™ 10% acid-resistant brick coupled with a 90% SEMPLATE™ tile (for example, a STEBBINS of Watertown, N.Y., salt-glazed vitrified tile). The tiles may be any desired dimension, such as nine inch by nine inch (9″×9″) or nine inch by twelve inch (9″×12″) tile, the tile dimensions being larger or smaller depending on the intended use.
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto.
This application is a continuation of application no. PCT/US2004/007696, filed Mar. 30, 2004, which claims the priority of application Ser. No. 60/461,419, filed Apr. 10, 2003, and each of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60461419 | Apr 2003 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US04/07696 | Mar 2004 | US |
| Child | 11230935 | Sep 2005 | US |
