Patent Application
20240424543
The present invention relates to methods and apparatus for fabricating and retrofitting dome shaped buildings using coiled rebar.
The use of freestanding dome shaped buildings is becoming increasingly popular. In contrast to conventional rectangular buildings, dome shaped buildings have a large interior space which is free from obstructions such as columns or other supports. Conventional dome structures are formed by inflating a flexible liner, applying a stabilizing layer on an interior surface of the liner, forming a reinforcing mat of rebar interior of the flexible liner, and then applying shotcrete over the reinforcing mat. Once the shotcrete is cured, the dome is self-supporting.
Although dome shaped buildings have many advantages, forming the reinforcing mat can be expensive, time consuming and labor intensive. For example, the reinforcing mat is typically formed by overlaying pre-cut lengths of rebar adjacent to the stabilizing layer and then tying them together with wire. The pre-cut lengths of rebar are commonly in a range between 6 meters and 12 meters. In some applications, the rebar must be custom cut to specific lengths for proper placement and fitting. The custom cutting, storing, and tracking of different lengths of rebar is expensive and time consuming. In turn, it takes multiple people to handle the pre-cut rebar sections and move them to the desired position for placement. In addition, by using pre-cut rebar sections, which can number in the hundreds or thousands for large projects, it is necessary to overlap and tie together opposing ends of separate rebar sections to form continuous lengths. The required overlapping of the rebar results in additional material cost. Furthermore, the movement, placement, and tying of the rebar sections is expensive, time consuming, and labor intensive. In addition, the rebar is weakest where it is tied together. As such, by using multiple pre-cut rebar sections that must be tied together, additional rebar and/or larger rebar must be used to compensate for the extensive tying. Additional problems also exist.
Accordingly, what is needed in the art are methods and apparatus for fabricating dome and other shaped buildings that solve one or more of the above problems associated with forming of the reinforcing mat.
A first independent aspect of the disclosure includes a method for fabricating or retrofitting a building that includes:
In one embodiment, the structure includes an outer perimeter wall of a preexisting building.
In an alternative embodiment, the preexisting building is a storage silo.
In another embodiment, at least a portion of the interior surface of the outer perimeter wall has a dome or cylindrical configuration.
In another embodiment, the structure includes a stabilizing layer disposed on at least a portion of an interior surface of an inflated form.
Another embodiment includes, spraying a cementitious material over the uncoiled section of rebar secured to the structure.
In another embodiment, the coil of rebar comprises a single, continuous strand of rebar having an uncoiled linear length of at least 50 meters, 100 meters, 250 meters, 500 meters, 1,000 meters, 1,500 meters, 2,000 meters, 2,500 meters or 3,000 meters.
In another embodiment, the uncoiled section of rebar secured to the structure has a linear length of at least 20 meters, 50 meters, 100 meters, 250 meters, 500 meters, 1,000 meters, or 1,500 meters and the coil of rebar has a uncoiled linear length of at least 20 meters, 50 meters, 100 meters, 250 meters, 500 meters, 1,000 meters, or 1,500 meters.
In another embodiment, the uncoiled section of rebar and the coil of rebar comprise a single, unitary, continuous strand of rebar.
In another embodiment, the coil of rebar comprises a single, unitary, continuous strand of rebar coiled into a coil, the coil having a maximum diameter of at least 1 meter, 1.3 meters, 1.6 meters, 2 meters or 2.5 meters.
In another embodiment, the coil of rebar comprises a continuous strand of rebar, the continuous strand of rebar having a nominal diameter of at least 9 mm, 11 mm, 13 mm, 15 mm, 17 mm, 19 mm, or 21 mm.
In another embodiment, the inflated form comprises a flexible, foldable, sheet, at least a portion of the inflated form having a dome or cylindrical shaped configuration when inflated.
In another embodiment, the method includes forming the structure by spraying one or more layers of a material on an interior surface of an inflated form.
In another embodiment, the material being sprayed comprises a polymeric foam.
In another embodiment, the method includes connecting a secondary rebar to rebar hangers extending from the structure, wherein securing the uncoiled section of rebar to the structure comprises securing the uncoiled section of rebar directly to the secondary rebar.
In another embodiment, connecting the secondary rebar to the rebar hangers comprises:
In another embodiment, the step of uncoiling the section of rebar from the coil of rebar comprises:
Another embodiment includes raising the basket assembly having the coil of rebar positioned thereon to an elevated position adjacent to the structure of the building before rotating the coil of rebar for uncoiling.
Another embodiment includes moving the basket assembly relative to the structure while concurrently rotating the coil of rebar positioned on the basket assembly so as to uncoil the section of rebar while the basket assembly is moving.
In another embodiment, rotating the coil of rebar comprises:
In another embodiment, the mechanical lift and the coiled-rebar dispenser are each electrically coupled to a controller, the controller being programmed to automatically correlate movement of the basket assembly by the mechanical lift with rotation of the coil of rebar by the coiled-rebar dispenser.
Another embodiment includes passing the uncoiled section of rebar through a rebar straightener before securing the uncoiled section of rebar to the structure.
In another embodiment, the rebar straightener is disposed on the basket assembly.
In another embodiment, the step of passing the uncoiled section of rebar through the rebar straightener comprises passing the uncoiled section of rebar between a first pair of wheels and then between a second pair of wheels, the wheels straightening the uncoiled section of rebar to a desired extent.
In another embodiment, the coil of rebar has a central axis of rotation about which the coil of rebar rotates while the section of rebar is uncoiled from the coil of rebar, the coil of rebar being disposed on the coiled-rebar dispenser so that the axis of rotation is either substantially vertical or substantially horizontal as the coil of rebar is rotated.
In another embodiment, the basket assembly includes:
In another embodiment, the basket assembly further includes a deck supported on the platform, the deck being configured to receive and support one or more operators, wherein the deck can swivel relative to the platform.
Another embodiment further includes:
A second independent aspect of the present disclosure includes a system for dispensing coiled rebar, the system including:
a basket assembly configured for being lifted off of a ground surface by a mechanical lift, the basket assembly comprising:
In another embodiment, the rebar straightener comprises a first set of rotatable wheels and a spaced apart second set of rotatable wheels, the rebar straightener being configured to straighten a strand of rebar to a desired extent as the rebar is passed between the first set of rotatable wheels and the second set of rotatable wheels.
Another embodiment further includes a mechanical lift having an elongated arm, the basket being disposed on the arm, the mechanical lift being configured to raise, lower, and laterally move the arm.
In another embodiment, the elongated arm is a telescoping arm that selectively expands and contracts.
In another embodiment, the mechanical lift is a boom lift or a cherry picker lift.
Another embodiment includes a controller electrically coupled to the mechanical lift and the coiled-rebar dispenser, the controller being programmed to automatically correlate movement between the mechanical lift and the coiled-rebar dispenser.
Another embodiment further includes a controller electrically coupled to the mechanical lift, the coiled-rebar dispenser, and the rebar straightener, the controller being programmed to automatically correlate movement of the mechanical lift and the coiled-rebar dispenser with operation of the rebar straightener.
Another embodiment further includes a coil of rebar disposed on the rotatable spindle of the coiled-rebar dispenser, the coil of rebar comprising a single, continuous strand of rebar having an uncoiled linear length of at least 50 meters, 100 meters, 150 meters, 200 meters, or 250 meters.
Another embodiment further includes a safety rail upstanding and encircling around at least a portion of the deck.
In another embodiment, the basket assembly further includes:
In another embodiment, the deck is supported on the platform, wherein the deck can swivel relative to the platform.
In another embodiment, the platform pivots about a first axis of rotation and the deck swivels about a second axis of rotation, the first axis of rotation being orthogonal to the second axis of rotation.
A third independent aspect of the present disclosure includes a building structure having:
In another embodiment, the single, unitary, continuous strand of rebar completely encircles the chamber bounded by the outer structure.
In another embodiment, the single, unitary, continuous strand of rebar continuously encircles the chamber bounded by the outer structure at least 2, 5, 10, or 20 times.
In another embodiment, the length of the single, unitary, continuous strand of rebar is at least 100 meters, 250 meters, 500 meters, 1,000 meters, 1,500 meters, 2,000 meters, 2,500 meters or 3,000 meters.
In another embodiment, the continuous strand of rebar extends substantially horizontally along the interior surface of the outer structure.
In another embodiment, the continuous strand of rebar extends horizontally or in a helical pattern along the interior surface of the outer structure so as to completely encircle the chamber at least once.
In another embodiment, the outer structure comprises a layer of polymeric foam having the interior surface and having an opposing exterior surface.
In another embodiment, a sheet of flexible and foldable material that is at least substantially impermeable to gas is disposed on the exterior surface of the layer of polymeric foam.
In another embodiment, the outer structure has a dome or cylindrical configuration.
In another embodiment, the building is a storage silo.
A fourth independent aspect of the present disclosure includes a method for forming a building, the method including:
In one embodiment, raising the coil of rebar comprises:
In an alternative embodiment, rotating the coil of rebar comprises activating the coiled-rebar dispenser so as to rotate the coil of rebar and uncoil the section of the coil of rebar.
Another embodiment includes moving the basket assembly by use of the mechanical lift while the section of rebar is concurrently being uncoiled from the coil of rebar.
Another embodiment includes:
In another embodiment, the mechanical lift and the coiled-rebar dispenser are each electrically coupled to a common controller, the controller automatically correlating movement of the basket assembly by the mechanical lift and uncoiling of the rebar from the coil of rebar.
Another embodiment includes passing the uncoiled section of rebar through a rebar straightener before securing the uncoiled section of rebar to the interior surface of the outer structure.
In another embodiment, the step of forming the outer structure comprises:
A fifth independent aspect of the present disclosure includes a method for forming a building, the method including:
The present disclosure envisions that each of the alternative embodiments associated with the corresponding independent aspect can be combined in any desired combination and that each of the alternative embodiments associated with one independent aspect can also be combined in any desired combination with the other indent aspects.
Various embodiments of the present invention will now be discussed with reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope.
Before describing the present disclosure in detail, it is to be understood that this disclosure is not limited to particularly exemplified apparatus, systems, assemblies, methods, or process parameters that may, of course, vary. It is also to be understood that the terminology used herein is only for the purpose of describing particular exemplary embodiments of the present disclosure and is not intended to limit the scope of the disclosure in any manner.
All publications, patents, and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
The term “comprising” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.
It will be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “rebar coil” includes one, two, or more rebar coils.
In addition, unless otherwise indicated, numbers expressing quantities, constituents, distances, or other measurements used in the specification and claims are to be understood as optionally being modified by the term “about” or its synonyms. When the terms “about,” “approximately,” “substantially,” or the like are used in conjunction with a stated amount, value, or condition, it may be taken to mean an amount, value or condition that deviates by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01% of the stated amount, value, or condition.
As used in the specification and appended claims, directional terms, such as “top,” “bottom,” “left,” “right,” “up,” “down,” “upper,” “lower,” “proximal,” “distal” and the like are used herein solely to indicate relative directions and are not otherwise intended to limit the scope of the disclosure or claims.
Where possible, like numbering of elements have been used in various figures. Furthermore, multiple instances of an element and or sub-elements of a parent element may each include separate letters appended to the element number. For example, two instances of a particular element “10” may be labeled as “10A” and “10B”. In that case, the element label may be used without an appended letter (e.g., “10”) to generally refer to all instances of the element or any one of the elements. Element labels including an appended letter (e.g., “10A”) can be used to refer to a specific instance of the element or to distinguish or draw attention to multiple uses of the element. Furthermore, an element label with an appended letter can be used to designate an alternative design, structure, function, implementation, and/or embodiment of an element. For example, two alternative exemplary embodiments of a particular element may be labeled as “10A” and “10B”. In that case, the element label may be used without an appended letter (e.g., “10”) to generally refer to all instances of the alternative embodiments or any one of the alternative embodiments.
Various aspects of the present devices and assemblies may be illustrated by describing components that are coupled, attached, and/or joined together. As used herein, the terms “coupled”, “attached”, and/or “joined” are used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly attached”, and/or “directly joined” to another component, there are no intervening elements present. Furthermore, as used herein, the terms “connection,” “connected,” and the like do not necessarily imply direct contact between the two or more elements.
Various aspects of the present devices, assemblies, and methods may be illustrated with reference to one or more exemplary embodiments. As used herein, the terms “embodiment,” “alternative embodiment” and “exemplary embodiment” mean “serving as an example, instance, or illustration,” and should not necessarily be construed as required or as preferred or advantageous over other embodiments disclosed herein.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present disclosure, the preferred materials and methods are described herein.
Depicted in
Briefly stated, in one method of production, building 10 is constructed by first forming footing 12. With reference to
Mounted on the interior surface of the one or more stabilizing layers is a reinforcing mat of rebar which can be comprised of vertically orientated rebar and horizontally orientated rebar. More specifically, in one method of formation, strands of rebar are secured so as to extent vertically along the interior surface of the one or more stabilizing layers. Next, large coils of rebar are progressively uncoiled and secured to the vertical strands so as to be horizontally or substantially horizontally disposed. By securing coils of rebar (as opposed to short sections of rebar) to the vertical rebar, the rate of application of the rebar is significantly increased while simultaneously increasing the effective strength of the rebar. As discussed further below, other advantages also exist.
Once the matt of rebar is secured, one or more support layers are then applied over the interior surface of the stabilizing layer such that the reinforcing mat is embedded therein. In one embodiment, the one or more support layers is typically formed of a cementitious material such as a sprayable concrete or shotcrete. As needed, the process of applying a matt of rebar and then covering the matt of rebar with a stabilizing layer can then be repeated one or more times until the desired structural strength for the building is achieved.
Outlined below are more detailed descriptions and alternative methods for manufacturing concrete structures, such as building 10, which can incorporate domed features. Although the methods are primarily discussed with reference to the manufacture of annular domed shaped buildings, such as shown in
Footing 12 provides a foundation for building 10 and defines an outer perimeter thereof. In one embodiment, as depicted in
Also partially embedded within footing 12 so as to upwardly project from top surface 41 of wall portion 40 are a plurality of spaced apart reinforcing rods 31. As will be discussed below in greater detail, reinforcing rods 31 are used to facilitate a rigid connection between footing 12 and boundary wall 14. Reinforcing rods 31 typically comprise conventional steel rebar although other conventional reinforcing materials can also be used. Reinforcing rods 31 are typically spaced apart in a range between 25 cm to 100 cm, although other spacing can also be used based on building parameters.
Footing 12 is typically comprised of poured concrete having reinforcing embedded therein. In the embodiment shown, footing 12 has an inverted substantially T-shaped transverse cross section. In alternative embodiments, footing 12 can have any desired transverse cross section that satisfies the building parameters. For example, footing 12 should be dimensioned to withstand frost conditions and be designed in accordance with the size of the building and the weight bearing capacity of the underlying soil.
As previously mentioned, footing 12 outlines the perimeter or footprint for building 10. In one embodiment, footing 12 is placed in a circular path. In alternative embodiments, as will be discussed below with regard to final building designs, footing 12 can also be placed in a variety of other configurations such as oval, elliptical, polygonal, irregular, or combinations thereof.
In one embodiment, wall portion 40 of footing 12 may be placed completely underground or project a few feet above the ground surface. In alternative embodiments, wall portion 40 can vertically extend so as to form a wall around the base of building 10. For example, wall portion 40 can have a height of at least 0.5 meters, 1 meter, 2 meters, 3 meters, 4 meters, 6 meters, 8 meters, 10 meters, or be in in a range between any two of the foregoing. In this embodiment, entrance 19 (
It is generally desirable that prior to securing inflatable form 22 to footing 12, all equipment that will be used in the construction of building 10 and which is too large to be moved into the building area through an access, to be described below, be placed within the area of chamber 20 bounded by footing 12. Once the equipment is positioned, form 22 is spread over the equipment and secured to footing 12.
As depicted in
Form 22 has an interior surface 23 and an exterior surface 25 that each extend to an outer peripheral edge 46. In one embodiment, form 22 is comprised of a lightweight flexible sheet that can be at least substantially or fully impermeable to gas and/or liquid. The sheet can be formed from a cross laminate plastic, a reinforced plastic-coated fabric, such as a polyvinyl chloride impregnated Dacron, or any other suitable material. Furthermore, form 22 can be formed of one or more layers of material. Form 22 can typically be rolled or folded without plastic deformation and will automatically unfold when inflated as disclosed herein. As will become more apparent hereinbelow, form 22 may be reusable or may be left in place after forming building 10.
In one embodiment of the present disclosure, means are provided for securing form 22 to footing 12 in a substantially airtight engagement. By way of example and not by limitation, a loop 47 is formed at peripheral edge 46 of form 22. A line 48, such as a cord or cable, is passed through loop 47 so as to extend along peripheral edge 46. In alternative embodiments, line 48 can be secured to peripheral edge 46 by use of any one of a number of conventional techniques. Peripheral edge 46 having line 48 coupled therewith is positioned against exterior surface 42 of footing 12 so that form 22 covers the area bounded by footing 12.
A sheathed clamping cable 50 is then positioned against exterior surface 25 of form 22 above line 48. Clamping cable 50 is tensioned in a continuous loop so as to bias form 22 against exterior surface 42 of footing 12, thereby preventing line 48 from passing between clamping cable 50 and footing 12. In one embodiment, clamping cable 50 is disposed tightly against line 48.
Once clamping cable 50 is tensioned, a plurality of elongated clamps 52 are mounted to footing 12. Each clamp 52 has a substantially C-shaped transverse cross section with spaced apart apertures 51 formed along the length thereof. Clamps 52 are mounted against footing 12 so as to cover line 48 and clamping cable 50 with bolts 44 extending through apertures 51. A nut 54 is threaded onto the free end of each bolt 44 so as to securely bias each clamp 52 against footing 12. Clamps 52 thus prevent clamping cable 50 and/or line 48 from sliding off of footing 12 during the inflation of form 22.
One alternative embodiment of the means for securing form 22 to footing 12 is depicted in
As depicted in
Blower 57 is used to inflate form 22 so that a first air pressure is formed therein. In one embodiment, the first pressure is in a range between about ½ inch (1.25 cm) H2O to about 2 inches (5 cm) H2O of static pressure. In other embodiments depending on the weight and size of form 22, other pressures may also be used.
To enable access to chamber 20, a temporary access 32 can be formed on form 22, such as adjacent to air port 55. Mounted in substantially sealed communication with temporary access 32 is an air lock 33. In one embodiment, air lock 33 simply comprises a structure having a first doorway, a second doorway, and a compartment formed therebetween. As people enter and exit chamber 20 through air lock 33, only one of the first and second doorways is open at a time. As a result, air within chamber 20 cannot significantly escape through air lock 33. The pressure within chamber 20 is thus maintained within a desired safety range.
As previously discussed, where wall portion 40 of footing 12 upwardly extends to form a perimeter wall, it is also appreciated that temporary access 32 and/or air port 55 can be formed through wall portion 40 as opposed to through form 22. When building structure 10 is completed, air port 55 and/or temporary access 32 may eventually form entrance 19 or a window or can be sealed closed.
After form 22 is inflated, entrances, windows, and all other openings that are to be present on building 10 are marked on interior surface 23 of inflated form 22. In one embodiment, the various layers of rebar and/or other select layers can be applied so as not to cover the marked openings. As a result, the openings can be more easily cut out once construction of building 10 is completed.
Returning to
Although not required, in one embodiment to help ensure that stabilizing layer 24 initially secures to interior surface 23 of form 22 as stabilizing layer 24 is initially applied thereto, a bonding agent is applied in a layer over interior surface 23 of form 22. In one embodiment, the bonding agent comprises an acrylic latex bonding agent such as V-COAT available from Diamond Vogel Paint out of Orange City, Iowa. In other embodiments, the bonding agent can simply comprise as rewettable bonding agent that has adhesive properties when hydrated so as to help stick stabilizing layer 24 to form 22. Use of the bonding agent is most applicable when stabilizing layer 24 is comprised of a cementitious material.
In part, stabilizing layer 24 functions to initially stabilize form 22 and provided a basis on which additional layers can be built. Although not required, the material for stabilizing layer 24 can be selected so as to have insulative properties. In this embodiment, stabilizing layer 24 forms an insulation barrier which helps control the temperature within chamber 20 and prevents the formation of condensation on the interior surface of building 10 bounding chamber 20. The material for stabilizing layer 24 can also be selected so that form 22 can be removed after or during the development of building 10. Alternatively, the material can be selected so that stabilizing layer 24 permanently adheres to form 22.
Depending on the engineering design of building 10, stabilizing layer 24 can be formed as a single layer from a single application. Alternatively, stabilizing layer 24 can be comprised of multiple overlapping sub-layers of the same or different materials. For example, stabilizing layer 24 comprises a first stabilizing sub-layer 24a and a second stabilizing sub-layer 24b. First stabilizing sub-layer 24a and second stabilizing sub-layer 24b combine to form a single, substantially inseparable stabilizing layer 24. In yet other embodiments, it is appreciated that stabilizing layer 24 may not be required at all.
Stabilizing layer 24 is applied to inner surface 23 of inflated form 22 by initially spraying first stabilizing sub-layer 24a having a thickness in a range between about 1 cm to about 5 cm with about 1 cm to about 3 cm being more common. A plurality of spaced apart hanger 58 are then mounted on sub-layer 24a.
As depicted in
In one embodiment of the present invention, means are provided for securing hangers 58 to stabilizing sub-layer 24a. By way of example and not by limitation, outwardly projecting from back side 64 of base plate 60 are a plurality of spaced apart barbs 70. Barbs 70 are configured such that hangers 58 can initially be secured to stabilizing sub-layer 24a by simply pushing barbs 70 into stabilizing sub-layer 24a until base plate 60 rests against stabilizing sub-layer 24a.
In alternative embodiments of the means for securing hangers 58, barbs 70 can be formed with outwardly engaging teeth. In other embodiments, barbs 70 can have a spiral configuration or be replaced with hooks, spikes, adhesive pads, adhesive, and other conventional fasteners. Furthermore, it is appreciated that hangers 58 can be replaced with other hangers or ties used in conventional building practices.
Each hanger rod 66 is generally made of a flexible metal, such as aluminum, and is secured in a generally normal relationship to the plane of the associated base plate 60. Hangers 58 are secured to first stabilizing sub-layer 24a such that hanger rods 66 project inwardly from first stabilizing sub-layer 24a in substantially normal relation thereto.
Referring again to
Each hanger rod 66 of hangers 58 has a predetermined length. As such, during the application of second stabilizing sub-layer 24b, the operator is able to visually observe the depth of stabilizing sub-layer 24b being applied through observing the build-up depth along the length of hanger rods 66. Additionally, the relatively thin hanger rods 66 enable a uniform spraying of polymeric foam about hanger rods 66 without impairing uniformity, density, or layer thickness of the foam. Hanger rods 66 are made long enough to extend outwardly from the completed stabilizing layer 24 by a distance of at least 6 cm, 8 cm, 10 cm, 12 cm, 14 cm, 16 cm, 18 cm or in a range between any two of the foregoing. Other dimensions can also be used. It is also appreciated that markings can be formed along the length of hanger rods 66 so as to assist in forming stabilizing sub-layer 24b to a desired depth.
As a result of base plate 60 of hangers 58 being at least partially embedded within stabilizing layer 24, a reinforcing mat, as discussed below, can now be secured to hangers 58 without pulling hanger 58 off of stabilizing layer 24. It is also appreciated that in other embodiments base plate 60 of hangers 58 can be sufficiently secured directly to an interior surface 29 of stabilizing layer 24 so that base plate 60 need not be embedded within stabilizing layer 24. For example, in one embodiment, an adhesive or adhesive pads can be disposed on back side 64 of base plate 60. The adhesive or adhesive pads can then be used to secure hangers 58 directly to interior surface 29 of stabilizing layer 24.
As stabilizing layer 24 and/or other layers, as discussed below, are formed inward of inflated form 22, the weight of building 10 increases. In some embodiments, depending on the size and configuration of building 10, it is desirable to incrementally increase the air pressure within chamber 20 produced by blower 57 so as to support the increased weight load of the building while the various layers are applied and/or set to reach their supporting strength.
The air pressure, however, cannot be increased beyond the pressure limits of form 22 or, where applicable, the combination of form 22 and stabilizing layer 24. Accordingly, to enable the air pressure within chamber 20 to be safely increased, means are provided for reinforcing form 22 and/or support layer 24. By way of example and not by limitation, in one embodiment the means for reinforcing comprises reinforcing line embedded within stabilizing layer 24. In an alternative embodiment, the means for reinforcing comprises a retention assembly secured over form 22. The reinforcing line and retention assembly are configured to absorb at least a portion of the increased pressure load applied to form 22 and/or stabilizing layer 24. Further disclosure with regard to reinforcing line embedded within stabilizing layer 24 and a retention assembly secured over form 22 are disclosed in U.S. Pat. No. 6,840,013, issued Jan. 11, 2005, and entitled Building with Foam Cored Ribs and Methods which is incorporated herein in its entirety by specific reference.
As depicted in
More specifically, in one method for forming reinforcing mat 98, support strands 94 are first applied horizontally adjacent to and/or slightly spaced out from interior surface 29 of stabilizing layer 24 and are secured in place by being attached to hangers 58. That is, hanger rods 66 projecting from stabilizing layer 24 are bent around or are otherwise used to secure horizontal disposed support strands 94 in place. Although support strands 94 can be positioned directly against or adjacent to stabilizing layer 24, in one embodiment hangers 58 are used to secure support strands 94 at a spaced apart distance from stabilizing layer 24. As a result, as will be discussed below in greater detail, support strands 94/reinforcing mat 98 can be embedded within a support layer that is applied thereon.
Horizontal rows of support strands 94 are vertically spaced apart at locations between footing 12 and a top end of building 10. Although support strands 94 provide structural reinforcing, one of their functions is to provide a structure that supports first reinforcing strands 95 and second reinforcing strands 96. In this regard, support strands 94 are typically vertically spaced apart at a greater distance than what second reinforcing strands 96 are typically spaced. For example, rows of support strands 94 are typically vertically spaced apart by a distance between 20 cm and 60 cm with between 30 cm and 60 cm being more common. Other dimensions can also be used depending on the application. Depending on the size and shape of the building or structure being formed, support strands 94 are typically comprised of precut sections of rebar typically have a length in a range between 5 meters and 15 meters with between 7 meters and 12 meters being more common. Other dimensions can also be used depending on the application. The precut sections of rebar are lifted and then secured in place by hangers 58, as discussed above. Opposing ends of adjacent precut sections of rebar are overlapped and secured together by conventional rebar tying. The process continues on a single row of rebar sections connected end to end until a continuous loop or row is formed. A vertically spaced apart second row is then formed using the same process and so forth until all desired vertically spaced apart horizontal rows of reinforcing strands 96 are formed that are necessary to support first reinforming strands 95 and second reinforcing strands 96.
Next, first reinforcing strands 95 are mounted on support strands 94. The size and spacing of first reinforcing strands 95 depends, in part, on the size, configuration, and load capacity of the building and the amount of reinforcing needed. First reinforcing strands 95 also typically comprise precut sections of rebar having the same lengths as previously discussed above with regard to support strands 94. The precut sections of rebar are connected end to end in a generally vertical orientation with the adjacent ends being overlapped and secured together using conventional tying techniques. First reinforcing strands 95 can form a continuous arch that extends from footing 12, to a top end of the building/structure, and then back down to footing 12 at the opposing side of the building/structure or at some other location. In other embodiments, first reinforcing strands 95 may only extend from footing 12 to an upper end of the building/structure. However, the diameter of domes decreases with vertical elevation. As such, fewer first reinforcing strands 95 are needed at higher elevations to maintain general uniform spacing between adjacent first reinforcing strands 95. As such, first reinforcing strands 95 need not extend continuously from footing 12 to the top of the building/structure. Rather, the number and/or spacing between first reinforcing strands 95 can be staggered at different elevations. Other configurations and placement of first reinforcing strands 95 can also be used.
After mounting of first reinforcing strands 95, second reinforcing strands 96 are positioned and secured to first reinforcing strands 95. The size and spacing of second reinforcing strands 96 are again dependent in part on the size, configuration, load capacity, and other properties of the building. However, in contrast to support strands 94 and first reinforcing strands 95 which are typically comprised of precut sections of rebar typically having a length shorter than 15 meters, second reinforcing strands 96 can be applied to first reinforcing strands 95 as one or more continuous strand of rebar having a length of at least 50 meters, 100 meters, 250 meters, 500 meters, 1,000 meters, 1,500 meters, 2,000 meters, 2,500 meters or 3,000 meters or in a range between any two of the foregoing. Other lengths can also be used. The continuous second reinforcing strands 96 can be produced and mounted by progressively uncoiling a coil of rebar while concurrently securing the uncoiled rebar to first reinforcing strands 95. For example, depicted in
In the depicted embodiment, mechanical lift 102 comprises a base 106 having supports 108 extending therefrom. Each support 108 can comprise an adjustable leg 109 terminating at an enlarged foot 111 disposed on a floor/ground surface. Legs 109 are typically adjustable to enable leveling of base 106. Feet 111 are typically securely fixed to the floor/grounds surface, such as by using bolts, fasteners, clamps, or other anchors. By securing feet 111/legs 109 to the floor/grounds surface, mechanical lift 102 can have minimal size/weight but still be able to lift large weights without tipping or sliding. For example, in one embodiment, the floor/ground surface can be a concrete floor to which feet 111 are removably secured to using anchors, such as those discussed above. In other embodiments, depending on use, supports 108 can comprise wheels for use in supporting and/or moving mechanical lift 102.
Disposed on base 106 is an elongated arm assembly 110 having a first end 112 supported on base 106 and an opposing second end 114 having basket assembly 104 mounted thereon. More specifically, in one embodiment mechanical lift 102 also comprises a turntable 116 that is rotatably mounted on base 106. Turntable 116 can rotate horizontally about a vertical axis extending through base 106 over an angle of at least 180°, 270° or more commonly over 360°. First end 112 of arm assembly 110 is attached to and outwardly projects from turntable 116. As such, in one embedment, arm assembly 110 can rotate horizontally relative to base 106 about any desired angle.
First end 112 of arm assembly 110 is pivotably mounted to turntable 116 by a hinge 117. Hinge 117 enables arm assembly 110 to pivot vertically up and down relative to turntable 116/base 106 over an angle of at least 45°, 70°, or, most commonly, at least 90°. In the depicted embodiment, arm assembly 110 comprises a main arm 118 and one, two, three or more inner arms 119 that are telescopically nested within main arm 118. As such, main arm comprises a telescoping arm. In one embodiment, basket assembly 104 is hingedly mounted at the end of inner arms 119/second end 114 by a motorized joint 127. Motorized joint 127 enables controlled tilting of basket assembly 104 so that basket assembly 104 can remain horizontally disposed or otherwise angled as arm assembly 110 is pivoted at hinge 117. In alternative embodiments, end of inner arms 119/second end 114 can be securely fixed to basket assembly 104 so that no tilting is permitted between arm assembly 110 and basket assembly 104. In this configuration, as discussed below in more detail, portions of basket assembly 104 can be configured to mechanically tilt as needed.
Inner arms 119 can telescopingly expand out from and retract back into main arm 118 to selectively move basket assembly 104 further away from or closer to base 106. In view of the foregoing, arm assembly 110 is movable relative to base 106 so that basket assembly 104 can be moved in any desired direction and to any desired location relative to base 106. For example, in the depicted embodiment, first end 112 of arm assembly 110/basket assembly 104 can rotate horizontally over any desired angle, pivoted vertically, typically over an angle of at least 90°, and expended away from or contracted toward base 106. Thus, movement can be accomplished in any desired direction to any desired location by combining the different movement capabilities. It is appreciated that arm assembly 110 can also have other configurations. For example, in an alternative embodiment, arm assembly 110 can be provided with at least one, two, three, or more motorized joints along the length of arm assembly 110 for use in adjusting the position and movement of arm assembly 110/basket assembly 104. Such motorized joints are used in the arms of cherry picker lifts.
As is known in the art, mechanical lift 102 can be provided with one, two, three or more spaced apart motors 169 that control the above discussed movement of arm assembly 110. For example, one or more motors can be used to drive a hydraulic system(s) that facilitates the various movements of arm assembly 110. Such motors can be mounted on or within base 106, turntable 116, and/or arm assembly 110. A controller 162, as shown in
With reference to
During use, as depicted in
The length of rebar strand 190 used in the formation of rebar coil 128 typically varies based on the size and quantity of rebar being used. However, the lengths can be standard lengths or customized lengths. In one embodiment, the length of rebar strand 190 used in the formation of rebar coil 128 is at least 250 meters, 500 meters, 1,000 meters, 1,500 meters, 2,000 meters, 2,500 meters, 3,000 meters, or 3,5000 meters or is in a range between any two of the foregoing. Other lengths can also be used. Rebar coil 128 also has an outside diameter that can vary depending upon the size of rebar being used. In one embodiment the maximum outside diameter can be at least 1 meter, 1.3 meters, 1.6 meters, 2 meters or 2.5 meters or be in a range between any two of the foregoing. Other diameters can also be used.
Returning to
In one embodiment, coiled rebar dispenser 120 can be centrally aligned with arm assembly 110 while operation area 134 can be disposed at a first end 156 of platform 123 on one side of coiled rebar dispenser 120. In this configuration, to help balance and stabilize basket assembly 104, an optional counterweight 136 can be mounted on a second end 157 of platform 123 on a side of coiled rebar dispenser 120 opposite of operation area 134. However, in other embodiments, arm assembly 110 can be more centrally aligned between coiled rebar dispenser 120 and operation area 134. In this embodiment, counterweight 136 can be reduced or eliminated.
Returning to
Further portions of rebar strand 190 are then uncoiled from rebar coil 128 using coiled rebar dispenser 120 and are progressively secured to laterally spaced apart rows of first reinforcing strands 95 so that the uncoiled and secured rebar strand 190, which also corresponds to second reinforcing strand 96, is horizontally or generally horizontally disposed. Concurrently with the uncoiling of rebar coil 128, basket assembly 104 can be moved horizontally, e.g., moved horizontally along interior surface 29 of stabilizing layer 24 a distance commensurate with the length of rebar being uncoiled. Basket assembly 104 can be moved horizontally by one or more operators 170 using controller 162 to laterally move arm assembly 110 such as by rotating turntable 116 relative to base 106 (
In view of the foregoing, the operation can include uncoiling a section 152 of rebar from rebar coil 128 and then securing the uncoiled section 152 of rebar to the stabilizing layer 24, such as through support strands 94 and/or first reinforcing strands 95, while the uncoiled section 152 of rebar remains connected to the remainder of rebar coil 128 disposed on coiled rebar dispenser 120. Accordingly, during use, the uncoiled section 152 of rebar secured to stabilizing layer 24 can be of a linear length of at least 20 meters, 50 meters, 100 meters, 250 meters, 500 meters, 1,000 meters, or 1,500 meters while the linear length of the rebar remaining in the connected rebar coil 128 can be at least 20 meters, 50 meters, 100 meters, 250 meters, 500 meters, 1,000 meters, or 1,500 meters.
In one method of operation, one operator can use controller 162 to horizontally move basket assembly 104 while a second operator uses controller 162 or a separate controller to concurrently uncoil a corresponding section of rebar coil 128. In an alternative embodiment, as depicted in
In one method of use of this assembly, the movement of basket assembly 104 and the uncoiling of rebar coil 128 can be done in consecutive or staggered stages. For example, basket assembly 104 can be moved laterally a fixed distance and then stopped. Once the corresponding length of rebar has been secured to first reinforcing strands 95, basket assembly 104 is then moved again another fixed distance and the process is repeated. The lateral movement of basket assembly 104 can be manually controlled by the operator using controller 162. Alternatively, computer 164/controller 162 can be programmed to automatically move a lateral fixed distance, stop for a fixed time interval, and then move again the lateral fixed distance. The movement and stopping is continuously and automatically repeated so that the operator does not have to control movement of the basket assembly 104 or uncoiling rebar coil 128.
In another alternative, computer 164/controller 162 can be programmed to continuously horizontally move basket assembly 104 at an adjustable fixed speed while concurrently uncoiling rebar coil 128 at a corresponding rate. That is, basket assembly 104 can be continuously moved at a sufficiently slow rate that the one or more operators have sufficient time to secure the uncoiling rebar coil 128 to first reinforcing strands 95 without stopping lateral movement of basket assembly 104 until all or a desired amount of rebar coil 128 is mounted or the operator otherwise elects to stop movement of basket assembly 104.
The above process of uncoiling and securing is repeated until the one or more operators 170 return to and secure rebar strand 190 being uncoiled to the initially secured free end of the rebar, thereby forming a first continuous horizontal loop or row of the rebar. For example, depicted in
Again, the starting portion and the ending portion of second continuous horizontal loop 176B are overlayed by a distance D and secured together. Rebar strand 190 is then again sloped upward to a location for a third continuous horizontal loop or row 176B. The process is then continuously repeated until rebar coil 128 is completely uncoiled. A second rebar coil 128 can then be positioned on coiled rebar dispenser 120. The free tail end of the prior rebar coil 128 can then be tied to free front end of the new rebar coil 128 and the above process is continued. As loops/rows 176 are formed at higher elevations, the operators can vertically pivot arm assembly 110 upward and expand arm assembly 110 outward so that basket assembly 104 remains adjacent to stabilizing layer 24 so that the operators can easily reach and mount rebar strand 190 as it is being uncoiled.
In contrast to the free tail end of the prior rebar coil 128 being tied to free front end of the new rebar coil 128 by using conventional rebar tying wire, the opposing ends of the rebar coils can be connected together using a rebar mechanical coupler. For example, depicted in
Mechanical coupler 200 also includes a plurality of first bolts 214A that are spaced apart and threaded into encircling side wall 204 and a plurality of second bolts 214B that are spaced apart and threaded into encircling side wall 204. First bolts 214A are aligned with first channel 210 and advance therein as first bolts 214A are threaded into encircling side wall 204. Similarly, second bolts 214B are aligned with second channel 212 and advance therein as second bolts 214B are threaded into encircling side wall 204. During use, a free tail end 216 of a prior rebar coil 128A is received within first channel 210 while a free front end 218 of a new rebar coil 128B is received within second channel 212. First bolts 214A and second bolts 214B are then threaded into encircling side wall 204 so that first bolts 214A are firmly pressed against free tail end 216 of a prior rebar coil 128A and second bolts 214B are firmly pressed against free front end 218 of a new rebar coil 128B, thereby securely fixing together free tail end 216 and free front end 218.
Mechanical coupler 200 provides a substantially stronger connection between prior rebar coil 128A and new rebar coil 128B than the use of tying wire and thus provides increased strength to the finished reinforcing mat 98. In some embodiments, mechanical coupler 200 can result in the uncoiled prior rebar coil 128A and new rebar coil 128B functioning, with regard to strength properties, as a single, continuous strand of rebar. The use of subsequent rebar coils in the formation of reinforcing mat 98 can similarly be connected in series using additional mechanical couplers 200. Although rebar mechanical couplers are more expensive than the use of tying wire, because entire coils of rebar are used in the formation reinforcing mat 98, relatively few rebar mechanical couplers are required. In this case, the increased strength provided by the rebar mechanical couplers can more than compensate for the increased cost.
It is appreciated that rebar mechanical couplers also come in other configurations, known in the art, that can also be used in the present disclosure. For example, in other embodiments, the mechanical coupler can comprise a tubular coupler body that receives the free end of two separate rebar coils and secures them together by crimped engagement, threaded engagement, or a wedged engagement. Other configurations can also be used.
Depending on the size of building, the size of rebar used in rebar coil 128, and the location of where the rebar is being applied, a single coil of rebar coil 128 may continuously extend around the inner circumference of stabilizing layer 24, i.e., encircle compartment 20, at least 0.5, 1, 1.5, 2, 2.5, 3.5, 4, 4.5, 5, or 6 times or in a range between any two of the foregoing. Other values can also be achieved. The above process can be repeated until the desired number of continuous horizontal loops or rows are formed extending from footing 12 to the top end of the building. The vertical spacing between adjacent loops/rows 176 of the uncoiled rebar strand 190, i.e., second reinforcing strands 96, can depend upon factors such as the size of the rebar, the size of the building, and the load the building will carry. However, in some embodiments, the spacing between adjacent loops/rows can be at least or less than 3 cm, 5 cm, 10 cm, 15 cm, 20 cm, or 30 cm or in a range between any two of the foregoing. Other dimensions can also be used.
Furthermore, the vertical spacing between uncoiled rebar strand 190/second reinforcing strands 96 can vary along the height of building 10. For example, the wall of building 10 is subject to greater loads toward the lower end of the wall. As such, horizontal rebar strand 190/second reinforcing strands 96 may be spaced closer together at the lower end of the wall than at the upper end of the wall. In addition, depending on the size, configuration, and other engineering requirements of building 10, rebar of one or more different sizes can be used at different locations on building 10. For example, since the base of building 10 carries more weight, the uncoiled rebar strands 190/second reinforcing strands 96 can be larger and/or closer together at the base of building 10 than at the top thereof. However, in one method of forming building 10, all of the uncoiled rebar strand 190/second reinforcing strands 96 can be produced from the same size of rebar. The rebar is moved closer together or further apart to adjust for needed strength properties. Using only one size of rebar achieves a number of benefits. For example, using only one size of rebar eliminates or at least limits the need to order, store, and track different sizes of rebar. In addition, larger diameter rebar can be more difficult to uncoil and more difficult for operators to manipulate and tie. Furthermore, larger diameter rebar may require the use of larger coiled rebar dispensers. As such, using one size of rebar, which has a relatively smaller diameter, eliminates the problems associated with larger diameter rebar. Other benefits also exist.
It is appreciated that depending on the configuration of building 10 and/or structural features of building 10, such as doorways, windows, or other openings, the uncoiled rebar strand 190/second reinforcing strands 96 may not always or ever form a continuous loop at different elevations. For example, in some situations it may be necessary to cut the uncoiled rebar strand 190 and then start again mounting at a different location. As such, uncoiled rebar strand 190/second reinforcing strands 96 may form vertically spaced apart rows but the different rows may not all be continuous loops. Furthermore, each row or loop of uncoiled rebar strand 190/second reinforcing strands 96 are generally not disposed perfectly horizontally. That is, the terms “horizontally” and “vertically” when used in association with rebar placement herein refer to being generally or substantially horizontal or vertical, as would be understood by those skilled in the art. For example, rebar disposed horizontal or vertical may have a variance at different locations along the length thereof of +/−20 cm, 15 cm, 10 cm, or 5 cm depending on the specific application.
It is also appreciated that in alternative embodiments, modifications can be made to the configuration and method of forming reinforcing mat 98 (
It is also appreciated that basket assembly 104 used in the uncoiling and mounting of rebar coil 128 can have a variety of different configurations. For example, depicted in
Turning to
Deck 180 has a first end 181 and an opposing second end 182. Deck 180 is disposed on platform 123 with second end 182 being pivotably coupled to platform 123 so that deck 180 can horizontally pivot on top of platform 123. An arced track 184 is disposed at first end 156 of platform 123. First end 181 of deck 180 movably engages with and is supported by track 184. As a result, first end 181 of deck 180 with safety railing 186 can pivot laterally forward or rearward relative to platform 123. Because building 10 is commonly in the form of a dome having a curved outer wall, the ability to enable deck 180 with safety railing 186 to pivot forward or backwards enables the operators to precisely position deck 180 with safety railing 186 at a desired position from stabilizing layer 24 (
Basket assembly 104A can also include a rebar straightener 140 mounted on platform 123 at second end 157. As will be discussed below in greater detail, as rebar strand 190 is uncoiled from rebar coil 128 by coiled rebar dispenser 120, rebar strand 190 will have a resting curvature that is typically significantly smaller than the curvature of interior surface 29 of stabilizing layer 24. In this case, the resilient spring force of rebar strand 190 can make it difficult or even impossible for an operator to manually position and secure rebar strand 190 to first reinforcing strands 95, i.e., adjacent to interior surface 29 of stabilizing layer 24 (
Rebar straightener 140 can have a variety of different configurations. In the depicted embodiment, rebar straightener 140 includes a support 142 having a top face 143. A plurality of rotatably wheels are disposed on support 142 and specifically are disposed on top face 143. The plurality of rotatable wheels typically includes at least a first pair of wheels 144A and 144B that are adjacently disposed in horizontal alignment and a second pair of wheels 146A and 146B that are also adjacently disposed in horizontal alignment but that are spaced apart from first pair of wheels 144A and B. Each of wheels 144 and 146 has an annular perimeter groove 148 configured to receive rebar strand 190. One or more motors facilitate rotation and/or movement of wheels 144 and 146. Controller 162 can be electrically coupled to the one or more motors of rebar straightener 140 and can be used to control operation of rebar straightener 140. During operation, rebar strand 190, as it is uncoiled from rebar coil 128, is passed between the first pair of wheels 144A and B and then between the spaced apart second pair of wheels 146A and B which selectively straighteners, to a desired extent, rebar strand 190. That is, as is known in the art of conventional rebar straighteners, by selectively controlling the spacing between the two pairs of wheels 144 and 146 and/or the alignment between each pair of wheels 144 and 146, rebar strand 190 can be straightened to be either linear or have a desired resting curvature.
Basket assembly 104A also includes one, two, three or more guideposts 192 upstanding from platform 123. Each guidepost 192 comprises a post body 194 upstanding from platform 123 and a guide opening 196 passing through the upper end thereof. Guide openings 196 are sized so that rebar strand 190 can pass therethrough. Guideposts 192 are positioned to help guide and control rebar strand 190 as it uncoils from rebar coil 128 and extends to rebar straighter 140. Any desired number of guideposts 192 can be used that are necessary or helpful in guiding and controlling rebar strand 190 as it passes from rebar coil 128 to rebar straighter 140. Rebar straightener 140 is orientated so that rebar strand 190 exiting rebar straightener 140 is directed toward a front side of safety railing 186 for mounting by the operators disposed within operation area 188, as previously discussed with regard to basket assembly 104.
In the same manner as previously discussed with regard to basket assembly 104, controller 162/computer 164 (
In view of the foregoing, by using coiled rebar mounting assembly 100 or 100A or any combination or modification thereof, reinforcing mat 98 can be formed on or adjacent to interior surface 29 of stabilizing layer 24.
Depicted in
Basket assembly 104B includes a base support 230 which can be permanently fixed to or removably mounted on second end 114 of arm assembly 110 (
Deck 180 with safety railing 186 are disposed on first end 156 of platform 123 while rebar straightener 140 and spaced apart guideposts 192 are disposed at second end 157 of platform 123. Coiled rebar dispenser 120 is disposed on platform 123 between first end 156 and second end 157 and is configured to receive rebar coil 128 and dispense rebar strand 190 (
As previously discussed with regard to basket assembly 104A, during use one or more operators stand on deck 180 and secure rebar strand 190 passing out of rebar straightener 140 to stabilizing layer 24/first reinforcing strands 95 (
As with basket assembly 104A, deck 180 of basket assembly 104B is pivotably mounted to platform 123. Specifically, second end 182 of deck 180 is rotatably coupled to platform 123, such as by a swivel 244 having a second axis of rotation 246. As second end 182 of deck 180 pivots about second axis of rotation 246, first end 181 travels is an arc along curved track 184. This selective pivoting or rotating of deck 180 allows the operators to adjust the position of deck 180 relative to stabilizing layer 24 so that deck 180 is optimally position for operators on deck 180 to secure rebar strand 190 to stabilizing layer 24/first reinforcing strands 95. As previously discussed, rebar strand 190 is typically secured so as to be horizontally or substantially horizontally disposed.
In one embodiment, a driver 248 is provided for pivoting deck 180 about second axis of rotation 246. In the depicted embodiment, driver 248 comprises a hydraulic cylinder extending between platform 123 and deck 180. In alternative embodiments, the hydraulic cylinder can be replaced with a variety of other driver systems such as a pully system, lever, rack and pinion, lift, pneumatic cylinder, spool and cable system, or other drive systems commonly known in the art. It is noted that the second axis of rotation 246 is typically disposed orthogonal to the first axis of rotation 238 but can be disposed at other angles.
Depicted in
Basket assembly 104C includes base support 230 that can be permanently fixed to or removably mounted on second end 114 of arm assembly 110 (
As rebar coil 128 is rotated by rotor 252, rebar strand 190 is dispensed downward from rebar coil 128 and passes between wheels 144 and 146 of rebar straightener 140 for desired straightening of rebar strand 190. In this embodiment, rebar strand 190 can extend vertically as it extends from rebar coil 128 and/or after is passes through rebar straightener 140. In this regard, rebar straightener 140 can be mounted vertically as opposed to horizontally as shown in
Basket assembly 104C can be used for dispensing rebar that is used as previously discussed first reinforcing strands 95. That is, as shown in
As depicted in
Support layer 26 is typically comprised of a cementitious material. As used in the specification and appended claims, the term “cementitious material” is intended to include any material that includes cement. Cementitious materials typically include graded sand and/or any number of conventional additives such as fillers, fibers, hardeners, chemical additives, or others with function to improve properties relating to strength, finishing, spraying, curing, and the like. In one embodiment, the cementitious material comprises a sprayable concrete such as “gunite” or “shotcrete”. Stabilizing layer 24 can also be made of non-cementitious materials as long as they provide the required strength properties.
For efficiency, it is desirable that the material for support layer 26 be sprayable. For example, the cementitious material can be applied through a hose at high velocity which results in dense material having a cured compressive strength in a range between about 3,000 psi to about 10,000 psi. Alternatively, although less efficient, support layer 26 can be applied by hand, such as by use of a trowel, or other techniques.
Support layer 26 may be formed as a single application layer or as multiple overlapping sub-layers. For example, in one embodiment a first support sub-layer is formed over stabilizing layer 24 prior to the attachment of reinforcing mat 98. Once first support sub-layer is formed, reinforcing mat 98 is formed thereon. A second support sub-layer is then applied over the first support sub-layer so as to embed reinforcing mat 98 therebetween. In other alternatives, multiple sub-layers can be applied directly over reinforcing mat 98.
The various sub-layers of support layer 26 can be comprised of the same or different materials. Likewise, cementitious materials of different grade or properties can be used. Although not required, each successive sub-layer of support layer 26 is typically applied before the previous sub-layer is allowed to cure completely so as to effect maximum bonding between the successive sub-layers. The thickness of support layer 26 is in part dependent upon the size and configuration of building 10 and whether other layers or support structures are to be added.
It will be appreciated that two or more support layers 26 may be formed in building structure 10 so that building 10 has sufficient structural strength. As shown in
As previously discussed, although not required, in one embodiment as the various layers or materials are added to building 10, the air pressure within chamber 20 is periodically increased, through the use of blower 57 (
After completing building 10 thus far described, the various doorways, windows, and other openings can be cut through boundary wall 14. Inflatable form 22 may be removed from stabilizing layer 24, if desired, and a protective coating such as asphalt and/or a suitable paint can be applied over stabilizing layer 24 to protect it from moisture and ultraviolet degradation caused by exposure to the sun. Inflatable form 22 may then be reused. Alternatively, inflatable form 22 may be retained on the completed building 10 and, if desired, coated to provide additional protection to building 10. A further alternative is to remove inflatable form 22, apply a coating of cementitious material to the lower outer exposed portion of stabilizing layer 24 followed by a moisture barrier coating of asphalt over the entire structure and a final coating of paint for obtaining the desired appearance. The combination of stabilizing layer 24 with or without inflatable form 22 and with or without various outer coating are examples of outer structures of building 10. Further methods, details, and alternatives for forming buildings incorporating the methods herein are disclosed in U.S. Pat. No. 6,840,013 which was previously incorporated herein by specific reference.
In contrast to using the above process to fabricate new buildings, such as storage silos, the above process can also be used to retrofit existing buildings, such as conventional storage silos. That is, there are an extensive number of conventional storage silos and the like that have deteriorated over time and need to be retrofitted with a reinforcing structure to maintain their proper structural integrity. Retrofitting a preexisting building with a reinforcing structure using conventional techniques is expensive, time consuming, and very labor intensive. However, by using the process described herein, the needed retrofitting can be produced quicker, with less labor, and at a significant reduction in cost.
For example, depicted in
To retrofit building 262 with a reinforcing structure, hangers 58 can be mounted to interior surface 264 of perimeter wall 260 such as by use of adhesive or other attachment mechanism. The attachment can be made in the same alternative ways that hangers 58 can be attached to stabilizing layer 24 (
In turn, in the same manner as previously discussed with regard to
Finally, once reinforcing matt 98 is secured, support layer 26, such as previously discussed with regard to
Embodiments of the present disclosure can achieve a number of unique benefits. For example, using a continuous strand of rebar uncoiled from rebar coil 128 to form second reinforcing strands 96 of reinforcing mat 98, as discussed herein, significantly reduces the expense, production time, and labor needed to produce building 10 and/or reinforce perimeter wall 260 of preexisting building 262 and, more specifically, to produce reinforcing mat 89. That is, concurrently uncoiling rebar coil 128 and mounting the uncoiled strand thereof as reinforcing is substantially faster than conventional methods of mounting short precut strands of rebar. For example, using extended lengths of uncoiled rebar as reinforcing eliminates or at least limits the need to custom cut and then store and track different lengths of rebar. Furthermore, using coiled rebar mounting assemblies disclosed herein to support, position, unwind, and mount rebar from rebar coil 128 reduces the number of labors needed and helps eliminate downtime previously encountered in having to frequently retrieve short strands of rebar for mounting. In addition, using an elongated strand of rebar as opposed to multiple short strands helps eliminate wasteful over lapping and tying of rebar. Also, by reducing unnecessary overlapping and tying of rebar, the overall strength of the rebar mat is stronger, thereby enabling the size and/or amount of rebar to be reduced. Other benefits also exist.
Various alterations and/or modifications of the inventive features illustrated herein, and additional applications of the principles illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, can be made to the illustrated embodiments without departing from the spirit and scope of the invention as defined by the claims, and are to be considered within the scope of this disclosure. Thus, while various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. While a number of methods and components similar or equivalent to those described herein can be used to practice embodiments of the present disclosure, only certain components and methods are described herein.
It will also be appreciated that systems, processes, and/or products according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties features (e.g., components, members, elements, parts, and/or portions) described in other embodiments disclosed and/or described herein. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment. Rather, it will be appreciated that other embodiments can also include said features without necessarily departing from the scope of the present disclosure.
Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative assemblies, processes, products, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein.
The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. While certain embodiments and details have been included herein and in the attached disclosure for purposes of illustrating embodiments of the present disclosure, it will be apparent to those skilled in the art that various changes in the methods, products, devices, and apparatus disclosed herein may be made without departing from the scope of the disclosure or of the invention, which is defined in the appended claims. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims the benefit of U.S. Provisional Application No. 63/510,210, filed Jun. 26, 2023, which is incorporated herein by specific reference.
| Number | Date | Country | |
|---|---|---|---|
| 63510210 | Jun 2023 | US |
