TECHNOLOGICAL FIELD
The present disclosure relates to concrete placement. More particularly, the present disclosure relates to a system and related method for sensing, scanning, or otherwise monitoring concrete slab placement and guiding concrete slab finishers during finishing to achieve very flat and/or level concrete surfaces. Still more particularly, the present disclosure relates to a 3D scanning system for monitoring one or more stages of concrete placement and finishing and a method of guiding the placement and finishing process to arrive at a very flat and/or level floor.
BACKGROUND
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventor, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
Concrete slabs can include slab-on-grade, below grad, and elevated slabs. Slab-on-grade slabs involve placing concrete on the ground with a desired thickness or elevation and finishing the top surface of the concrete. Elevated slabs may involve placing concrete on formwork supported above the ground. In some cases, formwork may be temporary formwork that is removed after the concrete is placed and after final cure. In other cases, formwork may stay in place. For example, corrugated metal pans may be placed on top of supporting beams where the corrugated metal is sufficiently strong to support the wet concrete and worker and equipment loading when the concrete is wet and becomes a part of the floor when the concrete is placed. In some cases, composite slabs may be provided where steel studs are welded to the beams by securing them to a top side of the corrugated metal and the welded connection penetrates the corrugated metal to secure the stud to the beam. Other types of elevated slabs may include post-tensioned slabs or systems or concrete topping slabs. Still other types of elevated slabs may be provided.
Whether a slab is a slab-on-grade or an elevated slab, the flatness and levelness of the finished surface of the slab can affect a wide range of things relating to the construction of the structure and/or appearance of the finished concrete. That is, for example, particular types of flooring may have relatively stringent tolerances for the underlying slab flatness. For example, ceramic, porcelain, linoleum, laminate, or other types of tile may be sensitive to floor flatness. Installation of later components may also be sensitive to floor flatness. For example, interior wall systems or partitions and, in particular, functioning doors in those systems may be adversely affected if the slab is not flat enough. Exterior wall systems such as curtain wall systems and, in particular, window mullions inside sliding glass doors, may be particularly sensitive to slab flatness where the slab extends out beyond the structure and is used to support the exterior wall systems. In the case of polished concrete, floor flatness and/or levelness criteria may be particularly stringent to provide a uniform appearance.
When a slab is poured and is insufficiently flat, a large amount of construction time and cost may be incurred to correct the problem. For example, retroactive processes to address flatness problems may include concrete grinding to address areas that are overly high. Leveling compounds may also be used to fill in areas that are too low. Moreover, where slabs are intended to be exposed, these grinding and leveling processes may adversely affect the resulting appearance of the concrete by changing the amount of aggregate exposure in some areas relative to other areas and/or by looking patched where the leveling compound is present. Nonetheless, common practices involve utilizing these retroactive processes because it is often thought, particularly on elevated slabs, that specified floor flatness values are extremely difficult to achieve during the placing and finishing process.
SUMMARY
The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.
In one or more examples, a concrete finishing system may include a surface sensor configured to capture surface profile data of a concrete surface. The surface sensor may be arranged such that a concrete work area where concrete is being finished is within a field of view of the surface sensor. The system may include a depiction generator configured to generate a depiction of a surface profile of the concrete showing a variation in the flatness of the concrete surface. The system may also include a display configured to display the depiction.
In one or more examples, a method of finishing concrete may include arranging a surface sensor such that a work area for placement of the concrete is within a field of view of the surface sensor. The method may also include capturing surface profile data of a surface of the concrete during placement or finishing of the concrete. The method may also include generating a surface profile depiction based on the surface profile data and displaying the surface profile depiction. The method may also include informing personnel regarding a variation in height based on the depiction.
In one or more examples, a concrete slab may have a floor flatness value above 35 and may include a surface free of ground areas and free of filled areas. The slab may be formed by a method including arranging a surface sensor such that a work area for placement of the concrete is within a field of view of the surface sensor. The method may also include capturing surface profile data of a surface of the concrete during placement or finishing of the concrete. The method may also include generating a surface profile depiction based on the surface profile data and displaying the surface profile depiction. The method may also include informing personnel regarding a variation in height based on the depiction.
While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:
FIG. 1 is a perspective view of a work area on a concrete project, according to one or more examples.
FIG. 2 is a perspective view of the work area with concrete placed and initial forming of the concrete surface being performed and including a surface sensor, according to one or more examples.
FIG. 3 is a perspective view of the work area where the concrete is being finished with a bull float, according to one or more examples.
FIG. 4 is a perspective view of the work area after initial forming of the concrete surface and during capturing of surface profile data, according to one or more examples.
FIG. 5 is a view of a surface profile depiction captured after initial forming of the concrete surface, according to one or more examples.
FIG. 6A is a perspective view of a display displaying the depiction and including spot values, according to one or more examples.
FIG. 6B is a perspective view of a display displaying an image of the work area and including spot values, according to one or more examples.
FIG. 7 is a perspective view of a remediation operation based on the depiction of FIG. 6A, according to one or more examples.
FIG. 8 is a perspective view of the surface sensor having been relocated to a different vantage point on an opposite side of the work area, according to one or more examples.
FIG. 9 is a perspective view of the work area where the concrete surface is being further finished with a highway straight edge, according to one or more examples.
FIG. 10 is a view of a surface profile depiction captured after further finishing of the concrete surface, according to one or more examples.
FIG. 11 is a perspective view of the work area where machine finishing is being performed, according to one or more examples.
FIG. 12 is a perspective view of the work area where hand finishing is being performed, according to one or more examples.
FIG. 13 is a perspective view of the work area where further hand finishing correction is being performed in narrower areas, according to one or more examples.
FIG. 14 is a view of a surface profile depiction captured after machine and/or hand finishing of the concrete surface, according to one or more examples.
FIG. 15 is diagram depicting a series of floor flatness values, according to one or more examples.
FIG. 16 is a perspective view of the work area where floor flatness is being verified with a straight edge after placement, according to one or more examples.
FIG. 17 is a perspective view of a slab edge outside of a column row on an outside edge of a structure, according to one or more examples.
FIG. 18 is a cross-sectional view of a concrete slab with a floor flatness of 25 after finishing and showing aggregate arrangement in the slab and relative to a floor flatness of 50, according to one or more examples.
FIG. 19 is a perspective view of a slab such as that of FIG. 18 after grinding operations, according to one or more examples.
FIG. 20 is a perspective view of a slab such as a slab having a floor flatness of 50 after finishing, according to one or more examples.
FIG. 21 is a diagram depicting a method of placing and finishing a concrete slab, according to one or more examples.
DETAILED DESCRIPTION
The present disclosure, in one or more embodiments, relates to a system and method for placing concrete. The system may include one or more tools, devices, and/or machines for placing, striking off, leveling, and smoothing concrete. For purposes of monitoring and guiding the concrete placement, the system may include a three-dimensional scanner or other measuring system that periodically captures surface profile data. The surface profile data may be displayed and/or communicated to concrete placement personnel so they can take action to address surface irregularities or, in particular, flatness issues. The scanner may capture surface profile data throughout the concrete placement process and varying levels of precision may be considered at the various stages of concrete finishing. The system may provide a detailed on-the-fly surface profile never before available during concrete placement. As such, surface flatness and levelness or other finishing characteristics may be addressed during placement rather than after placement. This can save considerable time and cost on a construction product and can also provide an improved product with considerably flatter surface and a more uniform appearance.
Turning now to FIG. 1, a perspective view of a concrete project 50 is shown. As shown, the system 100 for placing concrete 54 may include one or more concrete tools such as finishing tools including a screed or strike off board 102 (FIG. 3), a bull float 104 (FIG. 3), a highway straight edge 106 (FIG. 9), a machine float and/or trowel 108 (FIG. 11), a hand float and/or trowel 110 (FIG. 12), level setting devices 112 (FIG. 1), and other such tools and systems. Moreover, while not shown, concrete 54 may be delivered to a work area 52 on a concrete project 50 via one or more concrete delivery trucks. Where the work area is accessible by the trucks, the trucks may deliver the concrete 54 directly to the project 50 via a chute on the back of the truck. Where the work area 52 is not accessible by the trucks (e.g., elevated floors, no roadway access, etc.), the trucks may deliver the concrete 54 to a hopper on a pump truck, which may pump the concrete 54 through a crane supported hose to the work area 52. Alternative or additionally, the trucks may deliver the concrete 54 to a hopper carried by a crane, to an auger, to a belt conveyor, or to another concrete conveyance system arranged to transport the concrete 54 from the truck to the work area. One or more of these trucks and conveyance systems may also be part of the system described herein.
Referring now to FIG. 2, the system may also include a surface sensor 114. The surface sensor 114 may be configured to capture surface profile data of the placed concrete 54 and produce a surface profile map depicting the surface profile. In one or more examples, the surface sensor 114 may be a three-dimensional laser scanner. The laser scanner may be arranged on a tripod 116, for example, at or near a work area 52 of a concrete project 50 allowing the scanner to capture surface profile data of the placed concrete 54. The three-dimensional scanner may include actuation features allowing the scanner to be activated to begin scanning and one or more indicators for signaling the operations of the scanner such as when the scanner actively scanning and/or when the scanner is complete. In one or more embodiments, the surface sensor 114 may include a visual display 118 reflecting the area it is scanning and allowing for adjustment of the orientation and position of the scanner to capture the work area 52. While a three-dimensional laser scanner has been provided other surface sensor devices may be used such as a lidar sensor, a series of digital cameras, or other devices capable of capturing and/or generating three-dimensional surface data of the placed concrete 54. Moreover, and depending on the nature of the surface sensor used, the surface profile data may come in one or more forms. For example, in the case of a scanner or lidar sensor, for example, the surface profile data may include point cloud data. In the case of multiple digital cameras, the surface profile data may include 2-dimensional data that may be combined based on information about the frame of reference of the multiple cameras and overlapping image data, for example. Still other forms of surface profile data that defines the profile of the surface may be captured and used.
The surface sensor 114 may include an onboard or remote depiction generator 120 for processing surface profile data and generating a depiction of the surface profile. For example, as shown in FIG. 5, the depiction generator 120 may generate a three-dimensional representation or depiction 122A of the surface profile that is suitable for displaying on a two-dimensional display. In one or more examples, the depiction 122A may be a heat map showing degrees (e.g., areas A-E) or amounts of deviation from an otherwise flat surface. For example, particular colors may be used for ranges of deviation from flat. Alternatively or additionally, the depiction may be a contour line map showing the boundaries between particular ranges of deviation from an otherwise flat floor. In still other embodiments, the depiction may be a three-dimensional visual display. In any case, the depiction generator 120 may be calibrated to adjust its level of precision depending on the stage of concrete placement it is being used to monitor. For example, when initially placing concrete and initially forming the concrete surface a screed or strike off board 102 may be used. With these tools and at this stage of concrete placement, deviations from flat may be expected to range from approximately ½ inch low to ½ inch high. However, when completing further finishing with a bull float 104 and/or a highway straight edge 106, deviations from flat may be expected to range from approximately ¼ inch low to ¼ inch high. Still further, when completing machine floating and/or hand trowel operations, deviations from flat may be expected to range from approximately ⅛ inch low to ⅛ inch high. In view of this, the depiction generator 120 may have larger ranges suitable for depicting ½ inch deviations during strike off and may have increasingly smaller ranges as the concrete placement process continues. In one or more embodiments, the depiction generator 120 may self-calibrate itself depending on the range of deviation is determines is present from the surface profile data. The depiction generator 120 may be a computing device that is a hardware component, a software component, or a combination of hardware and software incorporated into the surface sensor 114 as shown in FIG. 3. In one or more other embodiments, the depiction generator 120 may be part of a separate computing device that is in data communication with the surface sensor 114.
The system may also include an onboard or remote display 118 for displaying one of several depictions 122A/B/C. For example, in one or more embodiments, a separate computing device 124 such as a laptop, iPad, smartphone, or other computing device having a display 118 may be provided. The computing device 124 may be in data communication with the surface sensor 114 and may receive the depiction 122A/B/C (e.g., see FIGS. 5, 10, and 14) from the surface sensor 114 and/or may receive the raw scanner data from the surface sensor 114 and may generate the depictions 122A/B/C (e.g., see FIGS. 5, 10, and 14). That is, where the depiction generator 120 is present on the separate computing device 124, the computing device 124 may receive raw data such as point cloud data from the surface sensor 114. In either case, the computing device 124 may display the depiction 122A/B/C on the display 118 for review by onsite personnel. Alternatively or additionally, the display 118 may be present on the surface sensor 114, such as on a backside thereof, on an openable/closeable screen, or another location on the surface sensor 114, for example. Still other types of displays 118 may be provided.
In operation and use, the system 100 described above may be utilized to place concrete and to monitor and guide the concrete placement to arrive at a concrete product with a suitably flat surface. With reference to FIG. 21 and supporting FIGS. 1-20, a method 200 of concrete placement may be provided. As shown in FIG. 21 and depicted in FIG. 1, the method may include preparing the work area 202. For example, a ground surface may be prepared by grading, flattening, and/or filling with a base material. Elevated slab work areas may be prepared by placing or erecting concrete formwork in the form of temporary or permanent formwork. In addition, reinforcing bars may be placed in the work area by arranging the reinforcing on supporting chairs, tying the reinforcing together, and otherwise securing the reinforcing to be encased in concrete. In one or more embodiments, the reinforcing may extend in a single direction or multiple directions and may include temperature and shrinkage reinforcement and/or structural reinforcement may be provided. Preparing the work area may also include setting level setting devices 112. For example, as shown in FIG. 1, boards may be secured to depth stands and adjusted to define a depth or thickness of concrete above the formwork. These level setting devices 112 may be used to guide pouring of the initial concrete to assist with arriving at a suitably thick and generally uniform slab of concrete 54.
With continued reference to FIG. 21 and as depicted in FIG. 2, the method may include setting up a monitoring system 204. In one or more embodiments, setting up a monitoring system 204 may include placing a surface sensor 114 at or near the work area 52. The surface sensor 114 may be arranged, oriented, and directed to place the work area 52 within a field of view of the surface sensor 114. In one or more embodiments, setting up the monitoring system may include placing the surface sensor 114 adjacent to the work area 52 in a position to scan the work area 52 from the side. The surface sensor 114 may be arranged on a tripod 116, for example, and the tripod 116 may be placed on the formwork or other supporting surface generally adjacent the work area 52. The surface sensor 114 may be adjusted to be directed generally horizontally, but slightly downward such that the anticipated concrete surface is within a field of view of the surface sensor 114. While this setting up process has been described as being conducted before pouring of the concrete 54, it can be performed during or after pouring of the concrete 54 as noted by a comparison of FIGS. 1 and 2.
As shown in FIG. 21 and with continued reference to FIGS. 1 and 2, the method may also include placing the concrete 206. As shown, this may be performed using a hose 56 in fluid communication with a concrete pump truck, for example. In other examples, hoppers, wheelbarrows, or other concrete conveyance means may be used. The concrete 54 may be poured into the work area 52 to the desired thickness. In one or more examples, a vibration mechanism may be used to increase the flowability of the concrete 54 and to get the concrete 54 to flow under, over, and/or around reinforcing bars and other items embedded in the concrete 54.
During and/or shortly after placing the concrete, the method may include initial forming of the concrete surface 208. This portion of the method may include striking off the concrete with a screed 102, for example, to arrive at a generally level top surface of the concrete as shown in FIG. 2. That is, a screed 102 in the form of a long, generally flat metal straightedge or bar may be handled by two workers, for example, and lifted and dragged across the top of the concrete to scrape off and/or consolidate the concrete to a generally uniform surface. In some cases, the screed 102 may be dragged and bounced to even out the surface and in other cases, the screed may be a vibratory screed 102 that may more simply be dragged across the surface. In addition, smaller screeds on poles or rods may be used to push and pull concrete and scrap off the top surface, particularly at edges. Once the concrete is generally in its desired position with a rough, but generally uniform top surface, a bull float may be used as shown in FIG. 3, to begin the flattening process of the surface of the concrete.
During or after the striking off process above and/or during or after the bull float process above, but before the further finishing discussed below, the method may include capturing a surface profile of the concrete 210. Capturing a surface profile of the concrete may include actuating the surface sensor 114 to capture three-dimensional surface profile data. In one or more embodiments, this process may include scanning of the work area for a time ranging from approximately 30 seconds to 2 minutes, or from 1 minute to 1 minute and 35 seconds, or for a time of approximately 1 minute and 20 seconds. If efforts to take images/pictures while scanning, the time may be relatively longer such as 2 minutes, 4 minutes, 7 minutes, or 15 minutes. Still other amounts of time may be provided for the process. In one or more embodiments, the surface sensor 114 may remain stationary during this process.
The method may also include generating a surface profile depiction 212. This portion of the method may be performed by a depiction generator 120 that may receive the surface profile data and generate a three-dimensional depiction 122A of the surface that is suitable for a two-dimensional display. In one or more embodiments, and as shown in FIG. 5, the depiction generator 120 may generate a heat map showing high and low areas and the degree of high and low areas based on colored regions on the map. For example, red-hot areas may be substantially high areas and decreasing amounts of redness (e.g., orange and yellow) may depict areas that are high, but not as high. Cyan colored areas may be areas that are close to a midpoint between the high and low areas (e.g., the desired surface level) and low areas may be depicted with darker colors such as dark blue or purple areas. Lesser amounts of purple or blue, such as green areas may be areas that are low, but not as low as the darker areas, for example. Still other color profiles and uses of color to depict high/low areas may be used. For example, the opposite may be used where red-hot areas depict low areas and darker more purple areas depict high spots. Still other approaches to the use of color to reflect relative heights of a surface may be used. Still other approaches to depicting high and low areas may include a depiction including contours or dividing lines between the areas. In one or more embodiments, as shown in FIG. 6A, spot elevations may be provided throughout the depiction 122A showing the elevation at particular locations in the work area 52. In other examples, spot elevations may be provided and overlaid on an image of the work area as shown in FIG. 6B
The method may also include displaying the surface profile depiction 214. In one or more examples, this may include displaying the surface profile on a handheld display 118 such as a laptop, iPad, or other separate display device. In one or more examples, displaying the surface profile depiction may include displaying the depiction on a display of the surface sensor 114. Still other approaches to displaying the depiction may be provided.
With continued reference to FIG. 21, the method may also include informing placement and/or finishing personnel 216. That is, the depiction may show high and low areas and may help to identify particularly problematic areas. In one or more examples, informing placement and/or finishing personnel may include reviewing the depiction 122A by personnel or having the personnel review the depiction 122A. In other cases, informing placement and/or finishing personnel may include directing personnel to particular areas and informing them of the high/low nature of the area. It is to be appreciated that, at this stage of the process (e.g., during striking off), expectations for slab flatness may be to achieve a flatness within a selected tolerance, which may be a wider tolerance than the final slab flatness since further finishing procedures may be performed. As such, in one or more examples, informing placement personnel may include informing placement personnel of areas that are outside the selected tolerance, where the tolerance may range from, approximately 1 inch to -1 inch, or from approximately ¾ inch to -¾ inch, or from approximately ½ inch to -½ inch, or from approximately ⅜ inch to -⅜ inch. For later finishing procedures, such as during use of a bull float 104 and/or highway straight edge 106, the tolerance may be reduced (e.g., ⅜ to -⅜, or ¼ to -¼, or 3/16 to -3/16, inches) and for even later finishing procedures, such as during machine floating/troweling or hand floating/troweling, the tolerance may be further reduced (e.g., 3/16 to -3/16, or ⅛ to -⅛, or 1/16 to -1/16, inches).
As depicted in FIG. 7, the method may also include remediating high and low areas 218. For example, based on the informing step above, placement and/or finishing personnel may address high/low areas by removing/adding concrete, respectively, to the high/low areas. FIG. 7, for example, shows personnel addressing a particularly high area along a future wall location.
In one or more examples, the method may also include repositioning the surface sensor 220. That is, as shown in FIG. 8, the surface sensor 114 has been moved to an opposite side of the work area 52 and arranged at an elevated vantage point (e.g., a story above the work area). In one or more examples, this may be performed to clear out of an area where additional concrete 54 is being placed and/or to provide a different perspective on the concrete surface where, for example, some areas suffer from an obstructed view, for example. Still other bases for repositioning the surface sensor may occur. The repositioning process may include removing the surface sensor 114 from its position, moving it to a new position, and setting up the surface sensor 114 using the same or similar steps as the method step of setting up the monitoring system 204.
The method may also include further finishing of the concrete surface 222. For example, as shown in FIG. 9, the surface of the concrete may be further finished using a highway straight edge 106, for example. A highway straight edge 106 may include a relatively wide blade with a smooth and flat bottom surface pivotally secured to the end of a long pole. The blade may be dragged along the surface of the concrete 54 by placement or finishing personnel to smooth out the surface. The highway straight edge 106 may further flatten the surface of the concrete 54 and may be used to create a surface that meets a higher flatness tolerance than the earlier processes (e.g., strike off and bull float).
The method may include repeating several of the processes 224 described above during or after the process of further finishing the concrete, but before the process of machine or hand finishing discussed below. That is, for example, the steps of capturing a surface profile 210, generating a surface profile depiction 212, displaying the depiction 214, informing placement and/or finishing personnel 216, and remediating high/low areas may be repeated 218. However, the tolerance used at this stage of the process may be slightly lower or tighter, as described above. As shown in the depiction of FIG. 10., the variance in the high/low regions may be reduced as compared to the depiction 122A of FIG. 5 (e.g., areas A-C as compared to A-E) and the surface profile depiction 122B may begin to look more uniform and/or with fewer regions that vary from the desired surface elevation or with regions that vary less from the desired surface elevation.
The method may also include machine finishing of the concrete surface 226. For example, as shown in FIG. 11, a walk-behind power float or trowel 108 may be used. In one or more examples, a riding power float or trowel may be used. In one or more examples, finishing personnel may wait for concrete to being to “set up” before engaging the concrete surface with a power float or trowel. In one or more examples, this waiting period may end when bleed water or moisture on the surface of the concrete has evaporated or otherwise cleared. Alternatively or additionally, the end of the waiting period may be determined by assessing the amount of impression left by a footprint (e.g., ¼ inch or less). As shown in FIG. 11, machine finishing of the concrete may include operating a power pan float or trowel blades on the surface of the concrete. The power pan float or trowel blades may include several spinning blades arranged in a fan-like formation. The blades may rotate under power of a motor in a smoothing fashion and the power pan float or trowel blades may be moved across the top surface of the concrete to finish the surface of the concrete. In particular, a pan may be placed below the trowel blades in a first machine finishing process and the pan may then be removed. A second machine finishing process may include operating the machine with the blades directly on the concrete surface.
The method may also include hand finishing of the concrete surface 228. For example, as shown in FIGS. 12 and 13, placing or finishing personnel may trowel the surface of the concrete with hand trowels 110. In one or more examples, personnel may use kneeling boards 126 to spread the personnel load on the concrete 54 to reduce and/or avoid creating depressions in the surface of the concrete. The hand trowels 110 may include handheld steel , wood, plastic, or other material blades that may further smooth out the surface of the concrete by bringing further cementitious butter to the surface. A relatively smooth and/or shiny surface may be created using the hand trowels and narrower or harder to access areas may also be addressed using the hand trowels. That is, for example, as shown in FIG. 13, a power float or trowel may be unable to access the concrete surface between the pipe stubs, and hand finishing tools may be used to finish the concrete in those areas.
During or after the machine finishing process above and/or during or after the hand finishing process above, but before substantial setting of the concrete, the method may include repeating several of the processes 230 described above. That is, for example, the steps of capturing a surface profile, generating a surface profile depiction, displaying the depiction, and informing placement and/or finishing personnel, and remediating high/low areas may be repeated. However, the tolerance used at this stage of the process may be slightly lower or tighter, as described above. As shown in FIG. 14, the variance in the high/low regions may be reduced (e.g., A/B as compared to A-C) and the surface depiction 122C may begin to look more uniform and/or with fewer regions that vary from the desired surface elevation.
The method may also include verifying the floor flatness 232. That is, as shown in FIG. 16, floor flatness may be verified or determined based on a 120 inch or 10 foot long straight edge. As shown in FIG. 15, various floor flatness (FF) numbers after the final finishing steps may be defined by the variance of the floor surface within the 120 inch distance. That is, as shown, an FF number of 20.2 may be defined by a floor surface that varies no more than an ⅛ inch every 30 inches. Similarly, an FF number of 27.9 may be defined by a floor surface that varies no more than ⅛ inch every 40 inches. Still further an FF number of 52.9 may be defined by a floor surface that varies no more than ⅛ inch every 60 inches and an FF number of 191.4 may be defined by a floor surface that varies no more than ⅛ inch in the full 120 inches. Other FF numbers may be defined by different gap dimensions (e.g., 3/16 inch, 5/16 inch, or ½ inch) as shown in FIG. 15. In view of the above and with reference to FIG. 16, a 120 inch straight edge may be used to inspect the slab surface at a series of locations and determine a floor flatness number. The inspection may be performed to confirm compliance with an architectural specification, for example. That is, an architect may specify a floor flatness and/or may specify a floor flatness and a minimum floor flatness. In the latter case, the specified floor flatness may be an average floor flatness and any particular floor flatness reading may be required to be above the minimum. In one or more examples, an architect may specify floor flatness values in particular areas, on particular levels of a building, or may otherwise define the area subject to the floor flatness specification. In view of the above, a concrete slab may include an entire level of a building or a particular area or zone of a level of a building, which may include one or more concrete pours. Alternatively, a concrete slab may include the extent of a particular pour, for example. Still other boundaries may be used to define a concrete slab.
The above system and/or performance of the above method may result in marked improvements in floor flatness, particularly on elevated slabs. That is, heretofore, systems for ongoing monitoring of concrete slab placement and finishing may have involved spot checking during the finishing processes. These spot-checking approaches may be subject to deflections in the formwork, when the spot checks are based on concrete thickness. Moreover, these spot checks, by their very nature, do not account for variations in the surface of the concrete at other locations (e.g., between the spots). As such, floor flatness during the placing and finishing process was subject to large variations in flatness that were not observable by the naked eye and, as such, often went entirely unnoticed and not detected until after the concrete was substantially set and floor flatness inspections were performed. With the present system, particular problematic areas such as areas around pipe penetrations as shown in FIG. 13, slab edges beyond column lines as shown in FIG. 17, as well as the entirety of the slab surface may quickly be assessed on an ongoing basis using the surface sensor and the associated surface profile depiction. This ongoing and complete or substantially complete surface assessment during the concrete placing and finishing process allows for floor flatness values to be achieved that were once thought not possible or practical. As such, much time and cost can be saved by avoiding the need for remediation of the slab after the concrete is substantially set. Moreover, the surface appearance of the concrete may be more uniform by avoiding grinding of high areas and/or leveling or filling of low areas. Where exposed concrete is desired, this is particularly game changing.
Regarding exposed or polished concrete, reference is made to FIG. 18. As shown, the aggregate within the concrete 54 may be generally evenly dispersed throughout the concrete and the rounded edges of the aggregate near the surface may be arranged generally tangentially with the surface. If a slab is poured as shown with an FF number of approximately 25 (e.g., as opposed to something closer to 35 or 50), floor grinding and/or filling may be performed to achieve the desired floor flatness. However, as shown in FIG. 18, this will cause further exposure of the aggregate in the high areas by grinding down to areas where the cross-section of the aggregate is larger, but in lower areas, the aggregate exposure may be relatively unchanged. As shown in FIG. 19, this can result in a non-uniform appearance on the surface of the concrete. In contrast, if the floor flatness of 35 or 50 is achieved from the outset by monitoring the placement and finishing of the concrete as described herein, floor grinding and filling may be avoided and a more uniform appearance of the concrete may be provided as shown in FIG. 20.
It is to be appreciated that concrete curing is a time sensitive process and that properties of cured concrete may often be determined at time frames such as 7 days and 28 days. In contrast, concrete setting can begin as soon as the concrete is mixed and/or as soon as the concrete is placed, for example. That is, as shown in FIGS. 11-13, the concrete may set sufficiently to support machine finishing equipment and workers a relatively short time after the concrete is placed. The present application contemplates performing the surface capture information and related depiction generation, display, informing personnel, and remediation steps before substantial and/or full setting or firming of the concrete which may be defined by a period of time suitable for finishing of the concrete surface. For example, concrete finishing may occur over a period of hours after concrete placement such as a finishing window of 0-12 hours, or from 0-8 hours, or from 0-4 hours, or from 0-2 hours, or from 0-1 hour, for example. As such, where reference to finishing or remediation operations are discussed herein that are prior to substantial setting, these operations should be considered to be performed within a suitable concrete finishing window described.
It is further to be appreciated that while depictions 122A, 122B, and 122C have been shown herein, these depictions are different only to the extent the slab profile is different. That is, any number of depictions may be generated throughout the process and should not be limited to the three depictions mentioned. Moreover, while depictions were suggested as being generated after initial formation of the concrete surface, after further finishing, and after machine or hand finishing, additional or fewer depictions may be used and the repeating of the related steps may be performed accordingly. Moreover, in one or more examples, where a particular depiction shows that all areas fall within a particular tolerance, steps to inform and remedy the issues may be skipped. Still other steps may be skipped, repeated, and/or reordered as desired by the user.
As used herein, the terms “substantially” or “generally” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” or “generally” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of “substantially” or “generally” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is “substantially free of” or “generally free of” an element may still actually contain such element as long as there is generally no significant effect thereof.
To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S.C. § 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.
Additionally, as used herein, the phrase “at least one of [X] and [Y],” where X and Y are different components that may be included in an embodiment of the present disclosure, means that the embodiment could include component X without component Y, the embodiment could include the component Y without component X, or the embodiment could include both components X and Y. Similarly, when used with respect to three or more components, such as “at least one of [X], [Y], and [Z],” the phrase means that the embodiment could include any one of the three or more components, any combination or sub-combination of any of the components, or all of the components.
In the foregoing description various embodiments of the present disclosure have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The various embodiments were chosen and described to provide the best illustration of the principals of the disclosure and their practical application, and to enable one of ordinary skill in the art to utilize the various embodiments with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present disclosure as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.
Patent Application
20230160155
