The present invention is directed to seismic foundation frame, a cementitious supporting form made therefrom and methods of making and using the form.
This present disclosure pertains to foundations and methods of preparing and producing a foundation. Installation of a foundation, for even a modest-sized structure, usually requires the time and efforts of numerous specialized trades and individuals, presenting the added challenge of organizing numerous specialized individuals to cooperate in an efficient manner. Despite the availability of modern construction machinery such as cranes, pumps, concrete mixers, and form works, the construction industry is currently dependent primarily on manual labor of professional contractors that operate the machinery and tools. Thus, current concrete construction is very costly and time consuming.
These skilled laborers construct structures using expensive methods and materials, such as reinforced concrete and masonry forms, that are generally rectilinear, thus significantly restricting architectural designs. Thus, these costs increase significantly when constructing complex concave-convex surfaces, for example, that conventionally require the pre-construction of expensive formworks and iron reinforcement cages, further including their transport, assembly, and then casting. Additionally, virtually all conventional construction systems require skilled workers to constantly refer to site plans (blue-prints), and this practice is slow and expensive, often producing inconsistent results. The appearance and quality of one structure can vary from another built from the same site plans and materials.
Regulations require reinforcement of concrete structures with rebar and/or other structural materials. Preparation and accurate layout of these cementitious reinforcing structures is time consuming and difficult. For foundations, long pieces of rebar are typically configured along a length of the foundation and are tied together at intersections with wire-tie, by hand. This is an imprecise method and the rebar can shift out of its stress zone when the concrete is poured leading to structurally weak areas that are prone to cracking and failure under load. Concrete walls and other vertical structures also require reinforcement. Again, extended lengths of rebar are configured vertically and horizontal extended rebar is commonly tied to the vertical rebar. This is a very difficult process and accurate retaining the rebar in pre-engineered stress zone during pouring of the concrete is difficult as the rebar may shift in position thereby loosing accuracy of the position of the rebar conventionally. Concrete forms are typically used to define the perimeter location of a poured concrete structure. These forms are usually constructed on site out of wood and require support structures to prevent collapse of the forms from the weight of the concrete. Again, this is a very labor-intensive process and requires additional materials to be brought to and removed from the work-site.
Historically, casting concrete foundations has necessitated the erection of two structures (forms): first; wooden, plastic, or foam forms are purchased, transported, assembled, and secondly; the concrete mix is poured or sprayed and is temporarily held in place by such forms. Following this, the forms are removed, and discarded or recycled, or cleaned, reshipped, stored and inventoried (Reference
Additionally, these forms are usually flat, thus significantly limiting design and construction diversity. Furthermore, conventional concrete forms have undesirable insulative characteristics that produce uneven heat dissipation during curing that can degrade the potential quality of the mixes' performance, and further limiting the critical factors required for obtaining the highest performance potential of concrete mixes. Furthermore, these conventional forms do not allow for visual inspection of the concrete mix casting state and quality, such as not revealing air pockets, voids, “bug holes”, etc., nor do they sufficiently protect the mix cast from the exterior environment, such as rain, driven wind, snow, debris, etc.
Within the prior art, using manual labor for construction is often very time-consuming, often requiring several months and, in some instances years, to complete. This can be due to differences in the laborers' skills, tolerances, sites, supervision, and techniques employed by those that work on the structures. Another important consideration is that conventional concrete construction systems typically result in significant amounts of wasted materials and time. For example, when concrete forms are used, they are commonly purchased in standardized off-the-shelf sizes, and often must be cut to meet site design requirements, resulting in waste of materials, labor, and time. Further, the materials require purchasing, inventorying, storage, and transportation, including their cleaning and discarding, or storage for subsequent re-use
A further limitation of prior art is the extensive and expensive site preparation required to accommodate the linear rigidities imposed by current methods. The concrete construction industry has a need for more sustainable automated onsite constructions systems that provides improved efficiencies, including use of building sites, and further providing significant improvements in sustainability durability, such as from seismic, wind, and snow load stability.
Additionally, within the prior art, constructing structures having complex multi-curved foundations and walls, particularly constructing with multiple temporary curved concrete forms for casting concrete walls, particularly those with small radiuses, is problematic and is cost prohibitive.
Materials such as reinforced concrete can be molded into curved structures, however conventional systems require costly individualized concrete forms to shape and support such materials in their initial fluid or plastic state. Since concrete forms have been generally constructed of lumber, it has been simpler and more economical to maintain the inherent rectilinear shape in the fabrication of such concrete forms and hence rectilinear concrete structures. Assembly of wooden forms in complex curved shapes requires a great expenditure of materials, cost, time, and effort.
Traditionally, buildings have been erected in generally rectangular configurations with the use of lumber, bricks, blocks and the like. These are rigid materials and may be most easily produced with straight sides and square corners, which requires that structures built with such materials also have the same straight sides and square corners of rectangular configurations. Structures built from conventional wood frame materials generally have relatively low energy efficiency and require a high level of maintenance. And tend to be fragile, and are susceptible to damage from storms, floods, earthquakes, and fire than are other reinforced concrete structures with curvilinear geometries.
In the art, it is known that curvilinear structures having complex 3-dimensional foundations and shapes such as having arches, domes, and vaults provides stress displacements and other numerous engineering benefits in structural integrity, air circulation, and aesthetics and design flexibility. 3-dimensional printed structures constructed with curved walls generally have higher potential resistance from earthquakes, high winds, snow loads, and the like, and additionally may be more energy efficient. However, the construction of such complex curvilinear structures has previously been unwanted or problematic and cost prohibitive.
The foundation framer rebar positioning system of the current invention provides the construction industry with more sustainable, and more ecological construction technology that constructs superior reinforced structures at lower time and costs, producing significantly less onsite waste and associated clean up, and employing more environmentally friendly materials, and requiring very low levels of energy. Employing concrete, the world's most ubiquitous material of our modern civilization, full architectural scale 3D concrete printing could herald an expansion to the 3rd industrial revolution: The Era of Mass Customization Construction.
The invention is directed to a seismic foundation framer, cementitious supporting form made therefrom and methods of using the cementitious supporting form to create a strong and durable composite cementitious form. An exemplary seismic foundation framer, or frame as used herein, comprises a ribbon that extends around the perimeter to form a rectangular shaped frame. The frame has an open construction with a plurality of openings to allow the concrete to flow therethrough and to provide increased surface area for concrete bonding and improved reinforcement. The frame may comprise a plurality of pin openings, and rebar openings for accurately receiving and positioning and retaining structurally reinforcing pins and or rebar respectively. These openings may be used to align a first frame with a second frame. For example, a first frame may be configured as a base frame and a second frame may be configured on top of the base frame and a pin and/or rebar may be extended through aligned openings in the top and base frames to align the frames and secure them in alignment, even when concrete is poured. In addition, the rebar and/or pin extending through adjacent frames may provide additional structural support, and provides an integrative structurally reinforced component. It is to be understood that frames may be coupled by rebar and/or pin at some offset distance from each other to create a cementitious supporting form that may include a containment sleeve for receiving and retaining a cementitious material therein. An exemplary seismic foundation framer may also comprise other openings through the ribbon, such as fastener opening for attachment of fasteners, such as hog rings to secure a containment sleeve thereto. Additional openings allow cementitious material to flow through the seismic foundation framer to further improve strength and integration with the cementitious material. An exemplary seismic foundation framer may comprise threaded openings for receiving a threaded component, such as a structural component, or a fastener, such as a bolt, threaded sill bolt, or screw pile bolt, for example.
An exemplary seismic foundation framer comprises a plurality of rebar retainers for accurately positioning and retaining rebar with a length axis of the rebar extending through the frame, from a first surface to the second surface, or substantially perpendicular to the plane of the frame, in one embodiment. An exemplary rebar retainer is formed from a portion of the ribbon that extends inward from the perimeter to form a rebar receiving channel with a channel loops at the extend end of the receiving channel. Rebar may be located in a channeled receiving opening in the outer perimeter of the frame and slid along the channel to the channel loop or extended end of the channel. The channel preferably comprises a retaining protrusion that extends inward toward the channel from the outside surface of the ribbon to create an interference fit for accurately and securely retaining the rebar in the rebar retainer. The protrusions effectively reduce the width of the rebar receiving channel thereby requiring the rebar receiving channel to slightly flex and open for the rebar to snap into to the rebar retainer. The rebar may be forced past the retaining protrusion and into the rebar retainer which may be configured at the extend end of the rebar receiving channel. The rebar retainer may be geometrically shaped to accurately position and secure the rebar therein, wherein the rebar retainer extends at least 180 degrees about the rebar, when the rebar is circular in cross-sectional shape. In an exemplary embodiment, the rebar retainer extends more than 180 degrees about the rebar, thereby forming the retaining protrusion along the channel, such as about 190 degrees or more about, about 210 degrees or more, about 240 degrees or more, no more than about 250 degrees and any range between and including the values provided. Rebar retainers may be configured to secure rebar at an offset distance from the outer perimeter.
An exemplary rebar retainer retains rebar at an offset from the outer perimeter frame. The channel loop or extended end of the channel may be configured at a setback distance to meet codes and regulations for the setback of the rebar. For example, side setback distances for the rebar or the channel loop of the rebar retainer may be between about 1.5 inches (3.81 cm) to 1.75 inches (4.45 cm), and the top and bottom setbacks may be a minimum of about ⅜th inch (0.95 cm) if depth is less than or equal to 8 inches (20.32 cm); and the required minimum concrete cover is h inch (1.27 cm) if depth is more than 8 inches (20.3 cm) according to ACI Building Code. These offset distances may be scaled and configured as needed to meet applicable codes or regulations, as required. In addition, a seismic foundation framer may have rebar receiving retainers with a reinforcing density that meets and/or exceeds regulations.
An exemplary frame may be configured with rebar retainers at a density of about one per square foot or more, about two per square foot or more, about four per square foot or more, about six per square foot or more, about eight per square foot or more, and any range between and including the rebar density provided. Rebar spacing's may be adjusted as needed and may vary depending upon application and as needed to conform with engineering requirements and applicable codes.
An exemplary seismic foundation framer may have a length or width that is at least about 6 inches, 15.24 cm, or more, at least 10 inches, 25.4 cm, or more, at least about 20 inches, 50.8 cm, or more and any suitable range between and including the dimensional values provided. The frame thickness ranges between about 1/16 inch (1.58 mm) up to about ½ inch (12.7 mm), more preferably ranging between about ⅛ inch (3.18 mm) to ¼ inch (6.35 mm), and may be scaled as needed depending upon application and applicable regulations. As an option or optionally the rebar foundation frame may be scaled as needed depending upon application.
A plurality of seismic foundation framers may be coupled directly together to create a seismic foundation frame assembly, wherein the plurality of seismic foundation framers are directly adjacent to each other or touching each other. The plurality of seismic foundation framers may be secured to each other by a fastener, such as a wire tie, zip tie, or bull nose securement ring, for example. The plurality of seismic foundation framers may be configured next to each other and/or one atop another.
Rebar may be a rod that is substantially rigid or a cable that is more flexible. Rebar may be polypropylene, Basalt, metal, and the like. A preferred rebar may be made of high temperature composite basalt which will has a coefficient of thermal expansion (CTE) that is very close to that of most cementitious mixes and provides improved tensile strengths that is twice that of steel reinforcement(s) and has improved mechanical strength gains, thermal stability, having significantly higher corrosion resistance and is compatible with a wide variety of additives, aggregates, admixtures, resins, and epoxies while simultaneously providing an electromagnetic insulator, particularly, solid composite basalt or advanced hollow basalt bars. The fusion point for basalt is about 984 to 1260 degrees C.
The seismic foundation framer systems is compatible with a wide variety of pre and post tensioning systems. Rebar and cables maybe coupled to or attached between a first and a second seismic foundation framer and tensioned between them. Rebar or other structural components may be attached with a fastener or may be threaded into a threaded opening in the seismic foundation framer.
An exemplary seismic foundation framer may be made out of a polymeric material, such as a polyolefin including, but not limited to basalt, fiberglass and or carbon fiber, and or plastic material selected from the group consisting of, polypropylene, polyethylene, polytetrafluoroethylene, polybutylene, terephthalate, polyamides, polyester, linear low density polyethylene, medium density polyethylene, high density polyethylene, ionomers, polyvinyl chloride, ethyl vinyl acetate, ethyl propyl copolymers, polyethylene copolymers, low density polyethylene, their copolymers, vinyl copolymers and mixtures thereof linear low density polyethylene, ionomers, polyvinyl chloride, ethyl vinyl acetate, ethyl propyl copolymers, polyethylene copolymers, low density polyethylene, their copolymers, vinyl copolymers polyolefin, polypropylene, polystyrene, polyethylene, polyurethane, polyvinyl alcohol (water soluble), basalt, silk, further including carbon, fiberglass, stainless steel, para-aramid synthetic fiber. Kevlar, graphene and their variances or other natural or hybrid materials and mixtures thereof. Polypropylene and basalt materials are most preferred. An exemplary seismic foundation framer made be made out of a thermoplastic material such as Polypropylene, thereby enabling melt forming of the frame. A preferred seismic foundation framer may be made out of basalt material which has high strength and a similar coefficient of expansion as cementitious mixes. As an option the seismic foundation framer of the current invention may be made out of reinforced concrete.
In addition, the surface of the frame may have surface deformations that improves the interface bond with a wide variety of concrete mixes. A smooth surface of the frame may be more likely to be a cleavage plane with the concrete and is not preferred. The surface of an exemplary frame may have an average surface roughness of about 0.2 mm or more, 0.5 mm or more, 1 mm or more, about 2 mm or more, about 4 mm or less and any range between and including the surface deformations values provided. Surface roughness may be measured with a surface profilometer, such as available from Zygo Inc. or Keyence Corporation.
As an option the seismic foundation frame of the current invention may comprise printed material thereon, such as logos, trademarks, and further include embedded computer chips (such as for accurately locating in 3-dimensional space), dimensional features and the like.
An exemplary seismic foundation framer provides many advantages and benefits over the prior art. An exemplary seismic foundation framer provides previously unavailable reduction or elimination of rebar dislodgment, moving out of place, particularly during the mix pour phase/process, and further reduces the formation of voids; i.e. cavities/bug holes. The seismic foundation framer provides previously unavailable higher potential resistance from earthquakes, high winds, snow loads, etc., further including improved load bearing characteristics. The seismic foundation framer of the current invention eliminates the need for hangers on a conventional form, significantly improves the casting environment, eliminates the need to install attachments within conventional forms. The current invention significantly expands the performance quality and significantly expands the range of castable cementitious mixes and other materials over the prior art, further including their associated admixtures and aggregates, etc. Instead of many prior art concrete and rebar spacing components accomplishing the task, the simplified seismic foundation framer of the current invention reduces it to one light-weight component to quickly accomplish multiple prior art tasks. The seismic foundation framer is compatible with a wide variety of prior art reinforcing and other conventional systems, and as an option the seismic foundation framer may be dropped in or inserted and positioned into a conventional prior art “mold” forms.
Cementitious Supporting Form
A plurality of seismic foundation framers may be spaced apart from each other and coupled together by rebar retained in and extending from rebar retainers to form an exemplary cementitious supporting form. The frames may be offset from each other by about 5 inches (12.7 cm), or more, about 6 inches (15.24 cm) or more, about 10 inches, (25.4em) or more, about 20 inches, (50.8 cm) or more, about 30 inches, (762 cm) or more and any suitable range between and including the frame offset distances provided. Frame spacing's may be adjusted as needed and may vary depending upon application and as needed to conform with engineering requirements and applicable codes. Note that when a cable type of rebar is used, the frame offset distances may be shorter than when rebar rod is used. The rebar cable and rebar rod may extend straight between frames or may extend such that the consecutive frames are not linearly aligned. The rebar cable or rod may bend between the frames to enable the formation of curvilinear structures. The seismic foundation system may comprise additional structurally reinforcing components such as structural reinforcing pins or other rebar extending through pre-engineered openings in the frame. The rebar or pins may extend out from any of the sides, and/or the top or bottom of the frame.
Note that the top of the frame may optionally serve as receiving channels for smaller diameter rebar, that may be employed or adjusted to maintain an accurate curvature and/or combined with a straight line of the foundation, or any combination as needed. As an option, employing stakes to bend the reinforcement and maintain the desired pre-bent position, such as staking both sides of a foundation, particularly when making small radiuses.
Pins may be positioned and secured within the seismic foundation framer such as by gluing, such as Epoxy® having a quick curing time. Pins may be secured in position by smaller reinforcement rods that extend into an opening in the pin and in some cases through an opening in the seismic foundation framer to eliminate any rotation of the structural pin. An exemplary structural pin may have any suitable length, such as between about 3 inches (7.62 cm) to about 6 feet (183), more preferably ranging between about 6 inches (15.24 cm) to 3 feet (91 cm), or as needed depending upon application. Optionally the structural pins can be threaded to be removably attached to a variety reinforcement member such as seismic stirrups, seismic hooks.
As an option the seismic foundation framer encompasses creating an interlocking keyway (male and female keyways) such as by the insertion of, such as but not limited to, a removable mold preferably having a sphere or an elongated dome on one or both ends to be inserted in the top center receiving channel of the seismic foundation framer. The pin could be a male keyway for a subsequent structure formed on top—or it could be a female keyway formed by a keyway form that is replaced temporary or reusable.
The current invention encompasses as an option having seismic hooks and or seismic stirrups positioned and secured in one of many possible configurations, depending on the specific application and/or regulations.
In addition, the seismic foundation framer system may comprise multiple levels of frames, wherein seismic foundation framers are positioned and stacked one atop another and secured together with wire-ties, structural pins, bullnose ring, glue, staple, etc. Intersecting forms may also be created, such as at corners or in junctions, such as T-junctions.
Containment Sleeve
An exemplary seismic foundation framer system comprises a flexible containment sleeve that extends along the sides and under the bottom of the frames. The sleeve may be a material that is specifically designed to provide permeation rates for the proper optimized curing rate of the particular cementitious mix employed, and is additionally compatible with fiberglass, carbon, rebar, etc. The reinforcing containment sleeve may comprise a woven fabric for example, such as a polymeric fabric. An exemplary containment sleeve may be composed of basalt and or plastic material selected from the group consisting of, polypropylene, polyethylene, polytetrafluoroethylene, polybutylene, terephthalate, polyamides, polyester, linear low density polyethylene, medium density polyethylene, high density polyethylene, ionomers, polyvinyl chloride, ethyl vinyl acetate, ethyl propyl copolymers, polyethylene copolymers, low density polyethylene, their copolymers, vinyl copolymers and mixtures thereof linear low density polyethylene, ionomers, polyvinyl chloride, ethyl vinyl acetate, ethyl propyl copolymers, polyethylene copolymers, low density polyethylene, their copolymers, vinyl copolymers polyolefin, polypropylene, polystyrene, polyethylene, polyurethane, polyvinyl alcohol (water soluble), basalt, silk, further including carbon, fiberglass, stainless steel, Kevlar®, graphene and their variances or other natural or hybrid materials and mixtures thereof. Polypropylene and basalt materials are preferred due to their compatibility with cementitious materials, durability as they do not oxidize like many metals, strength and density.
An exemplary containment sleeve may be fastened to the seismic foundation framer by securing clips, hog rings, stapler, glue, wire-tie, glue, etc. The containment sleeve extends around and under a plurality of frames to create a cementitious supporting form for receiving a cementitious material. In one embodiment, the sleeve is fastened to the frame by securing rings that pierce through the sleeve and around a portion of the frame having previously unavailable accurate 3-dimensional space defining means, such as for a foundation and or wall, and has a variety of attachments such as but not limited to gluing, stapling, hog ring securement, wire-tying, and further provides ease of attachment for a wide variety of cladding to the pre-engineered attachment points (holes/receiving channels) of the seismic foundation framer. Stainless steel hog rings are most preferred due to their strength and chemical stability. A bull nose gun may be used to secure the containment sleeve to the seismic foundation framer.
An exemplary containment sleeve is secured to a plurality of seismic foundation framers to produce a sleeved containment form that can receive and contain a wide variety of concrete mixes. The mix may flow into the sleeved form and through the frames and around the rebar and structural pins to form a structurally reinforced concrete member. An exemplary containment sleeve comprises sleeve apertures that allow concrete to penetrate therethrough to attach the containment sleeve to the concrete. The sleeve apertures may be sized to allow the concrete to bulge therethrough but not flow out of the apertures. In this way, the concrete and sleeve are attached, wherein concrete extends through the sleeve apertures. The size of the sleeve aperture may be specifically selected to provide attachment to the concrete mixture wherein a more viscous concrete mixture may accommodate larger sleeve apertures and a less viscous concrete mixture may require smaller sleeve apertures. In addition, the size and the density of sleeve apertures may be selected to allow the proper permeation for curing the concrete.
An exemplary containment sleeve comprises two or more layers and these two or more layers may each have apertures therethrough. The apertures may be offset to prevent cementitious material from seeping out from the containment sleeve. In an exemplary embodiment, the apertures are offset and the cementitious material extends through apertures in a fist layer but is then blocked by the second layer of the containment sleeve. The containment sleeve may be a woven or non-woven material or sheet that comprises strands of material. An exemplary containment sleeve may be a woven material having a weave pattern and venting apertures between the strands or yarns. An exemplary containment sleeve may be a non-woven material, such as a spunbonded polymeric material, such as polypropylene. The strands of the containment sleeve may be yarns that comprise a plurality of fibers or filaments. The cementitious material may extend around strands of the first layer to secure the containment sleeve to the cementitious material. The first and second layers may be made out of the same material but may have different weights, weaves and aperture sized, shapes and density. Alternatively, the first and second layers are made out of different materials. The cementitious material may extrude through apertures in the fit layer or inside layer to be retained by the second or outside layer. Cementitious material may also be configured in between the layers.
An exemplary containment sleeve comprises strands, which may be made up of yarns, fibers, filaments, or strips of material, and openings. Depending upon the application, the width of each strand preferably ranges between about 1 mm to about 4 mm wide, more preferably ranges between about 1.5 mm to about 3.5 mm wide. The thickness of layer of material, inside or outside layers, that may used in a containment sleeve, may be in the range of between about 0.01 mm to about 0.20 mm, more preferably ranging between about 0.02 mm to about 0.06 mm or as needed, depending upon the application.
An exemplary containment sleeve may comprise a translucent window for viewing the cementitious material or the components of the foundation, such as the seismic foundation framer or rebar and the like. The cementitious material may have color change properties and a window may allow determination of a curing state of the cementitious material.
The spacing or distance between the strands of the containment sleeve, that produce the desired venting apertures spacings may range from between about 0 mm to 5 mm, preferably ranging between about 0.25 mm and 3 mm, most preferably ranging between about 0.25 mm to 1 mm, or may be pre-engineered and spaced as necessary, preferably manufactured from polypropylene or bio-plastics H2O, CO2, or basalt, as needed to suit a particular mix and or application. Note the viewing window can range in width and length as needed depending upon application
The size, shape and density of apertures in the containment sleeve may be controlled to provide the required permeation for a given application, including the type of cementitious material and the environmental conditions. In addition, the shape of the sleeve aperture may be selected to provide good interface characteristics with the concrete extending therethrough and may be circular, oval, polygonal, elongated, such as slits, or cross-slits in the sleeve material.
An exemplary containment sleeve may also comprise printed material thereon, such as logos, trademarks, embedded chips, dimensional features and the like. A builder or manufacturer may desire to have their company name or logo on the sleeve material as this will be visible during construction. In addition, a sleeve may have dimension features, such as a scale or scale lines to allow for proper measurement and cutting of the sleeve material before or during installation, or for general measurement of a building structure, such as a sleeved form that utilizes a dimensionally marked sleeve. A containment sleeve may have marking to indicate distances, such a lengths or heights. A containment sleeve may have marking to indicate location(s) such as plumbing, electrical, stairs, fireplaces, panels (electrical junction boxes), windows, joints/seams, corners, doorways, columns, etc. As an option the external containment sleeve's surfaces may encompass surface impressions such as embossed patterns and or colors and/or logos on the external containment sleeves
An exemplary sleeve enables construction in a wide range of environmental conditions, much wider than conventional foundation methods, wherein the concrete is exposed directly to the ambient air. Foundations and other structures can be formed in wet and muddy conditions, including sand, or even during rain or under water, as the sleeve will protect the concrete from the elements and keep excessive water from compromising the concrete mixture. In addition, foundations and other structures may be formed in hot and dry conditions, wherein the sleeve regulates the rate of evaporation from the concrete and ensures an optimized cure rate as needed.
The current invention resolves many of the prior art concrete construction limitations by employing the innovative use of a seismic foundation framers attached to an external reinforced containment sleeve as disclosed herein.
The current invention significantly expands the performance quality and significantly expands the range of castable cementitious mixes and other materials over the prior art, further including their associated admixtures and aggregates, etc. In several specified embodiments encompasses that the current invention light weight quickly assembled external containment sleeve promotes faster casting rates and thus shorter construction schedules onsite over the prior art, thus reducing construction timelines at a reduced cost. The seismic foundation framer having external reinforcement fabric serves as a versatile light weight flexible reinforcing leave-in-place cast-in-place improved cementitious structural containment form(s), significantly improving a wide variety of reinforced concrete construction processes such as speed, accuracy, expands the structural “foundation” size ranges, and improves construction speed and diversity.
The containment sleeve may specifically designed for preferred curing environment, for optimized casting speeds and optimize the curing characteristics for a wide variety of cementitious (concrete) mixes such as, but not limited to, predictably obtain a higher percentage of the performance potential such as compressive strength, tensile strength durability, wall effect, grain boundary, impermeability, sheer strength, porosity control, oxidation resistance, erosion control, air and or argon, nitrogen entrainment, tension resistance, over the prior art and simultaneously provides fast casting on the construction site further includes high performance complex mixes such as having improved ductility, freeze thaw resistance, stress displacement, alkali resistance, and reducing porosity. The external containment sleeve predictably improves the casting outcomes of virtually all concrete mixes from generic concrete mixes to advanced highly complex high performance and ultra-high performance cement mixes, such as humidity regulating and memory return, air purifying cementitious mixes that previously required complex casting processes previously obtainable only in a controlled factory environment.
Employing the inventive vent regulating and containment sleeve as an apparatus encourages and promotes realizing a higher percentage of the mixes potential strength and other significant characteristics by controlling the mix's water percolation and uniformity to optimize the mix's curing rate (to control autogenous shrinking) and simultaneously improves the reinforced foundation dimensional accuracy and stability, i.e. “drying shrinkage”. This is particularly beneficial and advantageous when casting specialized (cementitious mix proportions), such as but not limited to obtaining an early high shear strength, and to obtain high toughness and high durability to onsite exposure conditions for, reducing construction timelines.
In an exemplary embodiment, a containment sleeve is used to control the degree of casting porosity, i.e. including controlling venting communication between the interior of the cast containment “sleeve(s)” to the external atmosphere, for controlling the specific mix or mixes' optimized curing characteristics as disclosed herein.
An exemplary containment sleeve may have yarns with a denier ranging between about 50 to 1200 denier, more preferably ranging between about 100 to 800 denier, most preferably ranging between about 350 to 700 denier preferably for casting foundations having dimensions up to about 10 inches, 25.4 cm, high by 14 inches, 35.56 cm wide or as needed depending upon the application. Polypropylene and basalt woven fabric reinforcement materials are most preferred.
The containment sleeve may have dimensions larger than about 10 inches, 25.4 cm high by 14 inches, 35.56 cm wide up to about 30 inches, 76.2 cm high by 30 inches, 76.2 cm wide or as needed depending upon the application, preferably ranging between about 1,100 to 4,000 denier, more preferably ranging between about 1,200 to 2,500 denier, most preferably ranging between about 1,500 to 2,000 denier for larger onsite casting foundations and beams, such as multi-frame foundation. Polypropylene and basalt woven fabric reinforcement materials are most preferred.
An exemplary containment sleeve may be configured to provide a controlled curing rate for high strength cementitious materials, such as super high cementitious materials having a strength of 60 kpsi and higher. These super high cementitious materials can only be formed when the rate of curing is controlled.
An exemplary containment sleeve can be used to quickly cast a wide variety of simple to highly complex mixes on site having narrower tolerance that previously only be able to be cast in a specialized factory environment having specific temperature and humidity controls. As an option, the current invention encompasses casting in an atmospherically controlled factory environment then transporting and assembling onsite.
The containment “sleeve's” materials and characteristics may vary at any location or section as needed such as having novel means for receiving settable mix materials, the external containment sleeves having accurate retaining means, the containment sleeve optionally having engaging folded sections or strips or other facings, with optional waterproofing means; e.g., coverings, coating, or foils, to provide a wider range of onsite casting environments and further having material characteristics that lowers manufacturing and shipping cost and improves diversity, predictability, accuracy, reliability, and improved speed over the prior art for improved control of onsite casting in real time containing a wide variety of cementitious materials such as but not limited to; constructing foundations, box beams, reinforcing ring foundations, tension rings, ringwalls, footings, slabs, walls and roofs is concerned, more particularly, provides previously unavailable structurally improved reinforced foundations and other reinforced concrete structures onsite in real time that is smaller, lightweight while at the same time offering pronounced rigidity or stiffness for construction implementation in fast, accurate reinforced concrete casting and material construction techniques.
The current invention further provides the ability to cast multiple grades of concrete sequentially, and accept a wide variety of viscosities and casting mixes.
The previously unavailable combination of the sleeve and seismic foundation framer creates an inexpensive box beam.
The current invention further significantly improves the speed, quality, and size of each structural reinforced foundations or sections over the prior art and simultaneously eliminates cementitious and non-cementitious materials leakage, and improves conformational tolerances, and improves related issues to designing workable concrete mixes and may be used for both new construction and rehabilitation, such as retrofitting and refurbishing a wide variety of structures, further including repairing foundations and or sections of foundations.
The current invention furthermore encompasses the seismic foundation framer providing improved resistance to soil subsidence, movement of the soil.
The containment sleeves provide accurate pre-engineered regulation and control of grout and/or mortar venting in between the containment sleeve's pre-engineered venting apertures (filament spacing) for accurately regulating the cementitious and or non-cementitious mixes overflow between the venting filaments (apertures). The containment sleeve provides a pre-engineered grout shield that regulates and controls grout and or mortar venting in between the spaced filaments (apertures) by regulating the amount of mix external venting characteristics in between the “sleeve's” (apertures) venting voids or spacing of the reinforcing filaments as needed.
Various cementitious masses serve various functions, and can be mass-constructed onsite in real time having fabric reinforced foundation products having improved structurally reinforcing concrete containment sleeve packaging methods.
The reinforced external containment sleeve of the current invention provides the ability to employ a wider variety of construction materials onsite in real time, such as cementitious materials, concretes, foams, plasters, insulations, stuccos, may be employed that was previously unavailable nor cost effectively constructed.
This innovation better adapts their full architectural scale designs to the realities of actual onsite concrete construction. Note that low concrete strength test results common in casting in hot weather are often caused by poor mix protection and fast initial curing of test specimens. Specifically tailored to general mix(es) as for example, for obtaining a high initial shear strength suitable for high speed casting by providing the minimal pre-engineered curing time between each casting layer, depending upon application.
The containment sleeve may employ multiple mesh layers, an inside layer and an outside layer, that are suitably positioned and bonded together depending upon application. Two sleeve layers are preferred, multi-layered sleeves are most preferred, and are preferably bonded having a 90 degree crossing angle providing improved cement to sleeve bonding characteristics. A multilayered containment sleeves may be designed with apertures that are not aligned and wherein apertures of a inside sleeve layer are not aligned with the apertures of the outside sleeve layer.
The current invention's external reinforced containment sleeve optionally accommodates improved moist curing water, fogger, applications eliminating surface erosion not limited to the top of the form as in the prior art, to predictably produce early structural loading and eliminates the necessity to structurally over-design having improved cost economy due to faster onsite construction speeds, such as from wind driven rain, and repels bulk water penetration (wicking of moisture).
In other exemplary embodiments encompasses employing a sleeve as an apparatus that significantly expands the casting mass and volume, as for example when casting; note that within the prior art is currently limited to casting high performance mixes up to about 50 cm thick (about 20 inches) and requires the immediate covering of the cast component such as with plastic sheeting material to prevent the rapid water loss to obtain or realize the potential casting characteristics for sustainable durability and to obtain maximum potential strengths.
Additionally, some cementitious casting materials specifications may not potentially be realized or obtained, such as without employing the current invention's methods and apparatuses including specifically pre-engineering the external containment sleeve curing characteristics.
The external fabric reinforced containment sleeves improves the mixes performance characteristics and structural performances such as but not limited to: 1) mixture proportioning; 2) mechanical properties; 3) time-dependent deformations; 4) flexural and shear behavior; 5) bonding behavior; 6) pre-stress losses; 7) the structural behavior of full architectural scale elements; 8) Improves the grain boundary; 9) Improves electrophysical bonding characteristics; 10) Improves electrochemical bonding characteristics, additionally the venting apertures may also be specifiable by design as needed.
Furthermore, the inventive external containment sleeves optimize a wide variety of concrete additives, including optimizing a wide variety of admixtures characteristics for improving and optimizing cement interface and expansion coefficients, such as self-consolidating (shrinkage-compensating) concrete. Additionally, the containment sleeve and the mix venting apertures regulate the slump control and produce less shrinkage.
The containment “form” may be used as a bulkhead form, and being lighter than plywood or steel forms, is easier, faster and more accurate to assemble onsite and cast in place, and requires no special formulations of concrete mix is necessary. The preferred mix slump ranges from about 0″ to 2.5″, a slump of up to about 3″ may be used with proper precautions. The most preferred casting slump ranges between about 0.0″ to 1.5″.
The current invention's frames and secured containment “sleeves” significantly expands the castable range of the concrete mix castable sections and cost less.
The current invention thus provides a variety of additional seismic upgrade characteristics by improving reinforcement and the concrete mixes' highly complex stress transfer characteristics, such as when constructing highly durable structures that may encounter tsunami, hurricanes, typhoons, tornadoes, earth quakes, mudslides, flooding.
The current invention encompasses that the constructed structures in some configurations may be subsequently flooded, dug out, and re-occupied.
In several specified embodiments encompasses that the current invention's reinforced containment sleeve(s) are more cost effective and ecological, leaving a smaller “carbon footcast” than the concrete construction systems of the prior art.
The inventive combination of containment sleeve and seismic foundation framer provides more accurate calculations of the mixes volume, improving conformational tolerances and simplifying inventory. The containment sleeves and the frames provide the simultaneous and or sequential casting of multiple mixes, or different grades of mixes. The frames and the containment sleeve system is compatible with a wide variety of micro-reinforcements providing structural improvements for using fiber-reinforced concrete (FRC) mixes to improve a wide variety of concrete performance characteristics such as improved stiffness and reducing deflection.
The inventive combination of containment sleeve and seismic foundation framer provides the ability to cast micro-reinforced concretes such as but not limited to basalt reinforcements such as rovings, ropes, filaments, twills, microfibers, woven yarns, carbon nanotubes (including their variations), and or graphene in a wide variety of reinforcing geometries such as in the form of tubes, nano-tubes, hollow tubes, stars, etc. When employing micro-reinforcements, concrete, instead of being a protection shell for the reinforcement, now becomes a protective and integrative structural component, combined with a wide variety of reinforcement(s).
The fiber-reinforced concrete increases structural stiffness and reduces deflection of casted concrete members as well as decreasing the stress in the reinforcement(s). This is particularly significant in thin cast reinforced concrete sections and other reinforced cementitious members, where the structures geometry and profile significantly contribute to controlling complex deflection characteristics. Such as curvilinear structures.
The external containment sleeves and seismic foundation framer improves the accuracy of reinforcement (rebar) placement and securement such as but not limited to the placement accuracy of plumbing, piping, conduit, electrical, earth tubes, fiber optics, fiber bundles, a variety of filament windings, and other improvements of mechanical properties, if necessary or required. Note conventionally the weakest point of a prior art foundation is its surfaces. Note that by employing the current invention external foundation surface is now the foundation's strongest area.
In an exemplary embodiment, adhesive or a cementitious material may be applied to the top of the foundation for attachment of an above structure. As an option adhesive or bonding encompass the spraying of a variety of cementitious adhesive materials in between the cast foundation having interlocking layers (cold joints) to provide an improved interlocking bond and provides additional reinforcement and strengthening to the interlocking surface bonding characteristics, improving an interlocking key-way interface and reduces water moisture penetration and long-term corrosion.
The containment sleeve further provides an improved bonding surface for additional inside and outside materials that may be applied to cast “foundations” as necessary to flow through the venting spacings in containment forms, such as but not limited to providing a suitable bonding surface for plasters, stuccos, clays/mud, tiles, stones, etc. as needed, and furthermore significantly reduces or eliminates cold joint interface limitations as needed in the art.
The combination of the synergistic containment sleeves and frames are compatible with a wide variety of man-made and indigenous aggregates, such as but not limited to crushed coral, pumice, scoria, stucco, plaster, clay (including local indigenous clays), etc., and are further encompasses a wide variety of recycled construction waste, recycled concrete (urbanite), glass, fibers, steel, and a wide variety of additives and admixtures, etc., as needed in the art and virtually any cementitious mix admixtures, aggregates, and additives including advanced reinforcements, such as micro-reinforcements, including carbon nanotubes.
An exemplary containment sleeve may comprise markings, such as dimensional markings to allow measurement of the amount used, and/or a general measure of a length used in construction. Marking may also include advertisements, company names and/or logos, and the like. In addition, a QR codes may be printed on the containment sleeve and may provide information about the containment sleeve and/or the construction project.
The containment sleeves am preferably dispensed from removably attached spools or dispensing rolls.
As an option or a variation of the current invention, the ends of the external sleeve may be tapered to fit (interlock) together as needed (not shown), such as overlapping the cast corners (interlocking) the cast layers.
An exemplary containment sleeves optionally may incorporate color changing dyes thus indicating the cementitious mix critical curing/casting temperatures and the curing rate in real time from the sleeves containing color changing materials, such as color changing from a hot red to a cooler green color depending upon the mix for accurately indicating the critical cast mix temperature in real time to optimize the mix's curing rate and uniformity (more uniform heat dissipation).
The external reinforced containment sleeves of the current invention encompass simplifying and verifying the onsite mix casting quality visual inspection process (i.e. viewing through the translucent sleeve). As an option the entire sleeve can serve as a see-through window, monitoring/metering window.
The containment sleeves accept a variety of in depth cementitious pigments (color/dyes). The external containment sleeve prevents unsightly concrete staining and discoloration. The external containment sleeve helps maintain a uniform edge and improves the aesthetic appearance of the concrete finish, and the external containment sleeve reduces or eliminates random surface cracking and edge curling cause by the concrete mix's normal volume change and significantly limits or eliminates the range of crack occurrence in general within the set area.
The external reinforced containment sleeve method and apparatus encompasses a wide variety of suitable fabric reinforcing materials, such as basalt, polypropylene, and other fabric reinforcing materials, having suitable configurations such as but not limited to, herringbone, cross-weave, plain twill, basket, satin, leno, mock leno, further including multidirectional weaves, unidirectional weave, or as needed.
An exemplary containment sleeve may be woven, or a non-woven and may have fibers or yarns orientation that are multiaxial or random. Fibers types are categorized by the orientation of the fibers used, and by the various assembly methods used to accurately position and hold the fibers together.
The external containment sleeves may optionally have gusseted sides (edges) composed of four sides of the same or different materials (composition) such as, foils, reflective materials, filaments, filament windings, fiber orientations and fabrics, fiber bundles, scaled venting apertures having different sizes and spacing's, crossing angles, weaves and patterns, such as the diameter(s) of the filaments and the weaves or pattern, as specifically needed, and a wide variety of other improved mechanical properties to optimize the curing environment each having their own uniquely tailored characteristics as needed depending upon the mix and application. As an option the current invention may employ pre-pleated or gusseted multi-sided external containment “sleeves.”
As an option the current invention may encompasses an anti-counterfeiting indicating component such as embedding fluorescent dyes that fluoresce, such as revealing coils, labels, etc. from the exposure from ultra-violet light or as an option may encompasses viewing window or port to visually reveals the “hoops,” “coils,” such as but not limited to logos, holograms, bar codes, embedded chips, factory codes, inventory codes, manufacturing codes etc.
The fabric reinforced external containment sleeve is preferably composed of woven basalt materials including composite basalt materials, such as basalt fibers, many possible combinations of fibers materials, resins, its variations such as but not limited to fiber reinforced or fiber bundles and filament windings preferably having basalt fabric and or resin systems, further including solid core and or hollow core basalt reinforcement, basalt microfibers and filaments reinforced composite basalt provides sustainability and weight savings within the inventive reinforced concrete structure. Additionally, basalt reinforcement(s) have lower shipping costs due to the lightweight nature of the material. A containment sleeve made from basalt permits cementitious mixes that heat up to about 150 degrees C. while curing and has the advantage of increase surface area of contact for the surrounding cementitious materials. Basalt containment sleeve are easier and faster to handle and install, significantly reduces or eliminates long-term reinforcement degradation and expensive long-term repair and maintenance (replacement costs).
High temperature composite basalt rebar reinforcement having coefficient of thermal expansion (CTE) is very close to that of most cementitious mixes and provides improved tensile strengths that is twice that of steel reinforcement(s) and having improved mechanical strength pins, thermal stability, having significantly higher corrosion resistance and is compatible with a wide variety of additives, aggregates, admixtures, resins, and epoxies while simultaneously providing an electromagnetic insulator particularly solid composite basalt or advanced hollow basalt bars further including basalt, meshes, ropes.
An exemplary containment sleeve may be folded over the top of the seismic foundation framer about an inch, and or folded over and touching, and or folded over and overlapping, or as needed depending upon the application (partial folding over and complete folding over).
An exemplary containment sleeve may surround or encapsulate two or more modular cementitious supporting forms or framer assemblies comprising two or more seismic foundation framers. The exemplary containment sleeve may be cut or pierced for inserting rebar or other joining component through the sleeve for coupling of assemblies or seismic foundation framers.
Construction Types
The foundation framer system may be employed for construction of a variety of above grade and or below grade foundations. The foundation framer system and cementitious supporting form may be a below grade foundation for a building, such as a dwelling, place of business or manufacturing facility, for example. The foundation framer system and cementitious supporting form may be used a wide variety of above structures such as but not limited to air form structures. 3 printed structures, conventional structures, walls (brick, block, stone), further including water tanks, reservoirs, small dams, stairs, etc. The attachment and or securement points may be used to attach the foundation to the foundation framers, sleeve, and or any combination therein.
The foundation framer system having a defined dimensional aspects may enable narrower or smaller excavation setbacks on a construction site than conventional foundation required supported forms to be installed before the cementitious material is poured.
As an example, the external containment sleeve (construction apparatus) having reinforcement may be pre-engineered by the described inventive measures of the current invention herein there is not or only a little further manufacturing is needed for optional removable attachments of foundations to above ground structures, such as but not limited to pneumatic (air form) having securement components may be necessary to attach or insert to the cast structure if needed such as but not limited to attaching “hoops” “loops”, eyelets, grommets, screw pile bolts, adjustable straps, flaps, pads, tabs such as, but not limited to, openings for cementitious filling or injection and or valves and valve connections, to cut edges, to fasten adjustable straps and latches, such as for permanently and or temporarily positioning the air form above the ring foundation having accurate positioning and adjustable securement onsite as needed further including the air form securement straps and fittings may be attached to the sleeve, may be attached to the frame, and is preferably attached (secured) to both sleeve and frame, or as needed.
An exemplary cementitious supporting form may be a foundation that is be manufactured offsite and transported onsite and assembled onsite.
An exemplary cementitious supporting form may be a foundation for emergency and/or temporary structures as it can be produced in a very short time. The structure may be temporary and removed from the foundation made with the cementitious supporting form. The cementitious supporting form may also be made offsite and used in a temporary location, such as for an emergency structure.
An exemplary cementitious supporting form is compatible with porting of the foundation. As an example, cutting through sleeve and slide in porting material (PVC, conduits, piping, etc.) and then attach (secure) the porting tube with a wire tie to the frame, attach to the sleeve, or any combination therein while the cast cures.
The reinforced external containment sleeve and framer of the current invention encompasses more complex stress transfer characteristics, and automatically self-conforms (self-compensates) to a wide range of ground conditions; i.e. contours, ground irregularities, soil subsidence, etc., further having the option of a leveling screw.
An exemplary containment sleeve may have attachments for the attachment to other structures such as an air form. These attachments, such as hoops” “loops”, eyelets, grommets, screw pile bolts, adjustable straps, flaps, pads, tabs, may be configured on the containment sleeve or attached to the containment sleeve. An attachment may extend through the containment sleeve and may be supported by the cementitious material or by a frame or other component within the sleeve. An attachment may be use to connect to another structure, such as a structure above the foundation such as, but not limited to, pneumatic (air form) having securement components that may be necessary to removably attach or insert to the cast structure if needed such as but not limited to attaching “hoops” “loops”, eyelets, grommets, screw pile bolts, adjustable straps, flaps, pads, tabs (not shown), such as, but not limited to, openings for cementitious filling or injection and or valves and valve connections, to cut edges, to fasten adjustable straps and latches, such as for permanently and or temporarily positioning the air form above the ring foundation having accurate positioning and adjustable securement onsite as needed, further including the airform securement straps and adjustable fittings may be optionally attached to the containment sleeve, may be optionally attached to the seismic frame, and is preferably attached (secured) to both containment sleeve and seismic frame, or as needed.
An exemplary seismic foundation framer can be used as a lintel. A lintel is a structural horizontal block that spans the space or opening between two vertical supports. It is often found over portals, doors, windows and fireplaces. Modern day lintels are made using prestressed concrete and are also referred to as beams in beam and block slabs or ribs in rib and block slabs.
The containment sleeve may comprise strands of highly oriented fibers that are oriented along the length of the strand or yarn. This high level of orientation increases the tensile strength and durability of the containment sleeve. Examples of highly oriented material are Spectra, available from Honeywell International, or Dyneema, from DSM Dyneema B.V.
A full architectural scale 3-dimensional seismic framer reinforced foundation/footing casting method and apparatus according to any claim or embodiment disclosed herein, having external reinforcing cementitious containment “sleeves” ensuring the mix test specimens are properly cured to better adapt their designs to the realities of actual field construction.
A containment sleeve may be a full architectural scale flexible external fabric reinforced cementitious containment sleeves and may by hydrophobic and repel bulk water penetration on contact, including wind driven rain, snow etc., by directing it away from the external reinforced cementitious sleeves' exterior surfaces.
A foundation formed from a cementitious supporting form as described herein, being tailored (customized) for highly complex cementitious casting characteristics to realize a higher percentage of the cementitious concrete mix potential performance characteristics including microstructure properties and materials improving a generalized quality assurance including optimizing, strengthening, protection, proportions, production, and delivery on the construction site, that previously has required casting in an atmospherically controlled factory environment, particularly when casting high performance and specialty concrete mixes.
A containment sleeve may be a full architectural scale flexible external reinforced cementitious containment sleeve having external reinforced gusseted side surfaces composed of different materials, filaments, filament windings, fiber orientation and fabrics, fiber bundles, sizes, apertures (spacings), each external reinforced cementitious sleeves that is flexible and having their own uniquely tailored characteristics as needed depending upon the reinforced foundation/footing casting application.
A containment sleeve may be a full architectural scale external fabric reinforced cementitious containment sleeve having a pre-engineered external venting and regulating apertures that permits improved reinforced cementitious foundation/footing casting characteristics for a variety of highly complex reinforced cementitious mixes such as memory return, air purifying (smog absorbing), self-consolidating concrete, and or humidity regulating cement mixes.
A containment sleeve may be a may accept a variety of in depth pigments (color dyes).
A containment sleeve may be a cement molding and casting sleeve for any concrete construction purposes with or without a cementitious supporting form or seismic foundation framer as described herein. A containment sleeve as described herein, may improve any cementitious, concrete process, making it faster, simpler, and more adaptable on the construction site in real time during any point in the reinforced concrete construction process.
A containment sleeve as described herein may be joined or bonded together or to any other portion of a cementitious supporting form, or other component on the work-site by a sleeve adhesive, a fastener, by heat sealing, cold sealing or ultrasonic welding.
A full architectural scale automated 3-dimensional foundation/footing casting external reinforcing containment mesh formwork element that is flexible method and apparatus according to any claim, wherein the mesh regions are defined by pre-engineered venting apertures of a specific size and spacings of the externally reinforced mesh foundation structure.
The full architectural scale automated 3-dimensional flexible external reinforcing containment sleeve foundation/footing casting method and apparatus according to any claim or embodiments herein, comprising providing a base reinforcing surface through which the mix material can selectively partially penetrate (forming a cementitious bonding surface), the reinforcing base surface for encapsulating the cast foundation/footing.
The full architectural scale method and apparatus of any claim encompasses that the cast in place leave in place external containment sleeve(s) are more cost effective and ecological, leaving a smaller “carbon footprint”, as for example the containment sleeve(s) may be specifically tailored to promote reducing thermal shock and provides a higher insulation per mass to volumes ratio reducing alkali-silica expansion, thermal cracking, and improving resistance to sulfate attack, and eliminating excessive water reduction and improving external water penetration resistance and improving durability and the cementitious mix's compatibility and long term sustainability.
As set forth in any claim, wherein enclosing the ends of the canst external flexible containment sleeve comprises attaching an adhesive glue or tape, tie-wire, staple, zip-tie, stitch, onto the containment sleeve.
The summary of the invention is provided as a general introduction to some of the embodiments of the invention, and is not intended to be limiting. Additional example embodiments including variations and alternative configurations of the invention are provided herein.
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of the invention.
Corresponding reference characters indicate corresponding parts throughout the several views of the figures. The figures represent an illustration of some of the embodiments of the present invention and are not to be construed as limiting the scope of the invention in any manner. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
Certain exemplary embodiments of the present invention are described herein and are illustrated in the accompanying figures. The embodiments described are only for purposes of illustrating the present invention and should not be interpreted as limiting the scope of the invention. Other embodiments of the invention, and certain modifications, combinations and improvements of the described embodiments, will occur to those skilled in the art and all such alternate embodiments, combinations, modifications, improvements are within the scope of the present invention.
The term ‘Retainer’ as used herein is defined as a thing that holds something in place.
The term ‘die’ as used herein is defined as
The term ‘Modular’ or ‘modular construction’ as used herein is defined as 1:of, relating to, or based on a module or a modular 2: constructed with standardized units or dimensions for flexibility and variety in use modular furniture 3: made from a set of separate parts that can be joined together to form a larger object: 3: Construction in which similar units or subcomponents are combined repeatedly to create a total system; 4. A construction system in which large prefabricated units are combined to create a finished structure. 5. A structural design which uses dimensions consistent with those of the uncut materials supplied. Common modular measurements are 4 inches (10.16 cm) to 4 feet (1.2 in).
The term ‘universal coupling’ ‘universal mount’ is defined as a form of coupling between two rotating shafts allowing freedom of angular movement in all directions.
The term “venting aperture” as used herein is a series of pre-engineered gaps or openings that regulates the desired cementitious mix quantity or rate of water evaporation, thermal transmission to accurately control the cementitious mix curing pre-engineered quality or rate of the cementitious mix and is defined by filament spacings, diameters, shapes, and configurations and encompasses pre-engineered venting apertures such as but not limited to square, rectangular or any combination therein.
The term “fabric” as used herein is defined in polymeric terms as a manufactured assembly of long fibers of carbons, aramid or glass, plastics, basalts or any combination of these, to produce a flat sheet of one or more layers of woven fibers such as filament windings. The woven fibers are arranged into some form of sheet, known as a fabric, to provide ease of onsite handling. Different ways for assembling woven fibers into sheets and the variety of fiber orientations possible lead to there being many different types of woven fabrics, each of which has its own mechanical characteristics.
The term “mesh” as used herein is defined as mesh is an open mesh, netting, web, webbing, used for reinforced containment sleeves and internal reinforcement to improve concrete stress transfer and displacement.
The terms “sleeve, sleeves, external sleeve, containment sleeves, or sleeve containment form”, as used herein, is an apparatus defined as a flexible leave-in-place cast-in-place external reinforcement and moldable containment form(s) tailored to specifically regulate the cementitious materials curing environment. The inventive external fabric reinforced containment sleeve of the current invention has pre-engineered venting apertures that functions as a highly selective transport membrane for a predictably controlling and regulating the encapsulated cementitious mixes evaporation rate and thermal exchange transmissions to the external environment etc. as needed.
The term “concrete” as used herein is a composite material composed of coarse granular material (the aggregate or filler such as sand, conglomerate gravel, pebbles, broken stone, or slag) embedded in a hard matrix of material (the cement or binder) that fills the space among the aggregate particles and glues them together. Concrete, as used herein, refers to a cementitious mixture that cures to form a rigid body.
The term cement or cementitious, as used herein, refers to cementitious mixtures including compounds that cure over time to hold aggregate or concrete in place. These materials include traditional Portland cement and other cementitious materials, such as fly ash, ground granulated blast furnace slag (GGBS), limestone fines and silica fume. These materials are either combined at the cement works (to produce a composite cement) or at the concrete mixer when the concrete is being produced (the cementitious product is called a combination in this case). Fly ash and GGBS are the most commonly used of these materials in the UK. These secondary materials are useful by-products of other industrial processes, which would potentially otherwise be sent to landfill. Using GGBS or fly ash in concrete, either as a mixer addition or through a factory made cement, significantly reduces the overall greenhouse gas emissions associated with the production of concrete
For purposes of this specification it will clearly be understood that the word(s) “option” “optional” or “optionally’ mean the subsequently described event of circumstances may or may not occur, and that the description includes instances where said event or circumstance occurs and instances in which it does not.
Rebar, as used herein, is an elongated support that may be circular in cross-sectional shape, such as a rod. Rebar may be metal, polypropylene, basalt or composite materials.
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The ribbon forms a plurality of rebar retainers 40 for retaining rebar to the seismic foundation framer. The rebar retainers comprise rebar receiving and retaining channel 42 that extends in from the outer perimeter 23 of the seismic foundation framer 12. The ribbon turns in from the perimeter forming a rebar channel opening 33. Rebar can be slid along the channel and then forced past a retaining protrusion 46 or protrusions that extend from the outside surface 31 of the ribbon 30 along the rebar channel 42. The rebar is then accurately retained in the rebar retainer 40 such as between the retaining protrusions and the channel loop 43, wherein the ribbon loops at the extended end of the channel.
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It will be apparent to those skilled in the art that various modifications, combinations and variations can be made in the present invention without departing from the scope of the invention. Specific embodiments, features and elements described herein may be modified, and/or combined in any suitable manner. Thus, it is intended that the present invention cover the modifications, combinations and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This application claims the benefit of U.S. provisional patent application No. 62/593,363, filed on Dec. 1, 2017; the entirety of which is hereby incorporated by reference herein.
Filing Document | Filing Date | Country | Kind |
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PCT/US18/63519 | 12/1/2018 | WO | 00 |
Number | Date | Country | |
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62593363 | Dec 2017 | US |