Not Applicable
The present disclosure relates generally to the art of concrete construction, and more particularly, to a system and method for facilitating the construction of walls, ceilings and other surfaces from concrete.
In the art of concrete construction, it is commonplace to form concrete walls, ceilings, and other concrete surfaces using shotcrete, also known as sprayed concrete or gunite. Shotcrete, which can refer to both the material and the construction technique itself, involves pneumatically projecting concrete or mortal at high velocity onto a surface, typically a surface that has been prepared in advanced by the placement of reinforcing material such as steel rods, steel mesh, or fibers, such that the sprayed shotcrete will encase the reinforcing material. Shotcrete has many advantages over other methods of concrete construction and offers many benefits in terms of speed, cost, and ease of installation in relation to conventional poured concrete techniques.
However, conventional methods of shotcrete construction suffer from several deficiencies, especially in relation to architectural projects requiring more complex designs or fine attention to aesthetics and detail. Unlike poured concrete where more complex shapes and designs can be achieved via the fabrication of molds, shotcrete is significantly less precise. As such, the primary applications of shotcrete have been in relation to industrial uses of concrete where aesthetics are of less importance, such as in the stabilization of excavation walls or cliffsides, or the lining of swimming pools prior to the placement of tile.
A major deficiency of shotcrete is that it is very difficult for even a skilled artisan to produce a shotcrete wall having different thicknesses at different points on the wall in order to produce a wall or other surface having arcuate, curvilinear, or other exotic characteristics across various dimensions. Previously, in order to accomplish this, protruding dowels, rods, or pins would be placed at various locations protruding from the shotcrete receiving surface to predetermined distances, optionally with wires tied therebetween, and the shotcrete installer would use the length of the rods and/or the wires tied therebetween as a gauge to produce a shotcrete wall having the desired depth at the desired locations. Following this, the shotcrete installer would adjust the wall using a hand tool in their best attempt to blend the areas of differing depths to produce the desired arcuate, curvilinear, or other exotic surface. This technique is extremely imprecise and labor intensive, and frequently fails to meet the aesthetic needs of the project. Further, to produce designs with more extreme arcuate, curvilinear, or other exotic characteristics may require an unwieldy amount of guide rods to be placed and may require such extreme labor and attention to detail, both before, during, and after the shotcrete spraying, that the advantages of shotcrete construction over poured concrete construction entirely disappear.
As such, it may be seen that novel shotcrete construction techniques which may remedy these and other deficiencies associated with the prior art are desirable.
To solve these and other problems, systems and methods of shotcrete construction are contemplated whereby, in an exemplary embodiment, guide rails are placed in proximity and forward to a shotcrete receiving surface, with the guide rails disposed directly in front of the shotcrete receiving surface being configured to be offset therefrom such that shotcrete may be sprayed against the receiving surface behind the offset guide rails to form an uninterrupted shotcrete surface. Following application of shotcrete to the receiving surface, a screed configured to engage with and traverse along at least two of the guide rails may be used to rod the shotcrete via a protruding region of the screed extending beyond the guide rails, thereby removing excess shotcrete and imparting to the shotcrete a contour at least partially defined by the configuration of the guide rails. Likewise, the protruding region itself of the screed may also be varied to further define the contour of the shotcrete. It may thus be seen that complex, precise, and even exotic architectural shotcrete installations may be created in this fashion by providing a suitable set of guide rails and screed, representing in a substantial increase in precision and speed over conventional architectural shotcrete techniques.
According to one embodiment of the present disclosure, a system for shotcrete construction is contemplated, the system comprising a plurality of guide rails configured for placement proximal to a shotcrete receiving surface and in substantially parallel alignment to one another, at least one of the guide rails having a spaced region configured to be forwardly offset from the shotcrete receiving surface such that when the spaced region of the guide rail is placed in front of the shotcrete receiving surface, shotcrete may be applied against the portion of the shotcrete receiving surface behind the spaced region, and a screed configured for simultaneous engagement with and traversal along at least a portion of at least two of the guide rails, the screed having a protruding region such that when the screed is engaged with and traversed along at least a portion of at least two chosen guide rails following application of shotcrete against the shotcrete receiving surface, the protruding region is operative to rod the shotcrete so as to impart a contour to the shotcrete at least partially defined by the configuration of the at least two chosen guide rails.
At least two guide rails may be configured for substantially vertical alignment proximal to a shotcrete receiving surface, with the screed configured for substantially horizontal simultaneous engagement with at least two guide rails. Each of the plurality of guide rails may be substantially identical configured such that the contour imparted to the shotcrete is substantially similar along the direction of the shotcrete surface substantially perpendicular to the substantially parallel direction of the guide rails. Alternatively, at least two of the plurality of guide rails may be substantially differently configured such that the contour imparted to the shotcrete is substantially dissimilar along the direction of the shotcrete surface substantially perpendicular to the substantially parallel direction of the guide rails.
More particular embodiments having at least three guide rails are also contemplated, with each of the least three guide rails being configured for placement at a regular predefined interval from one or more adjacent guide rails. In such embodiments, the screed may be configured to permit simultaneous engagement with and traversal along any adjacent pair of the at least three guide rails.
The screed may be configured to engage with and traverse along at least one guide rail via sliding frictional engagement. The screed may also be configured to engage with and traverse along at least one guide rail via coupling engagement. The protruding region of the screed operative to rod the shotcrete may also be configured to be one or more of: linear, arcuate, curvilinear, serrated, smooth, or combinations thereof.
According to another exemplary embodiment of the present disclosure, a method for shotcrete construction is contemplated, the method comprising at least the steps of (1) providing a plurality of guide rails in proximity to a shotcrete receiving surface in substantially parallel alignment to one another and a screed configured for simultaneous engagement with and traversal along at least a portion of at least two of the guide rails, at least one of the guide rails having a spaced region configured to be forwardly offset from the shotcrete receiving surface such that when the spaced region of the guide rail is placed in front of the shotcrete receiving surface, shotcrete may be applied against the portion of the shotcrete receiving surface behind the spaced region, the screed having a protruding region, (2) applying shotcrete to the shotcrete receiving surface; and (3) simultaneously engaging the screed with and traversing the screed along at least a portion of at least chosen two guide rails to cause the protruding region to rod the shotcrete and impart a contour thereto at least partially defined by the configuration of the at least two chosen guide rails.
These and other features and advantages of the various embodiments disclosed herein are better understood with respect to the following descriptions and drawings, in which:
Common reference numerals are used throughout the drawings and the detailed description to indicate the same elements.
According to various aspects of the present disclosure, systems and methods of shotcrete construction are contemplated, wherein according to an exemplary embodiment, guide rails are placed in proximity and forward to a shotcrete receiving surface, with the guide rails disposed directly in front of the shotcrete receiving surface being configured to be offset therefrom such that shotcrete may be sprayed against the receiving surface behind the offset guide rails to form an uninterrupted shotcrete surface. Following application of shotcrete to the receiving surface, a screed configured to engage with and traverse along at least two of the guide rails may be used to rod the shotcrete via a protruding region of the screed extending beyond the guide rails, both removing excess shotcrete and furthermore imparting to the shotcrete a contour at least partially defined by the configuration of the guide rails and which may be at least partially defined by the configuration of the screed.
Turning now to
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At least one of the guide rails 14 may have spaced region 16 configured to be forwardly offset from the shotcrete receiving surface 12 such that when the spaced region 16 of the guide rail 14 is placed in front of the shotcrete receiving surface 12, shotcrete may be deposited against the portion of the shotcrete receiving surface 12 beyond the spaced region. In this way, it may be seen that even when the guide rails 14 are emplaced prior to the spraying of shotcrete, such placement would not interfere with the ability of the applicator to apply a continuous shotcrete surface to the shotcrete receiving surface 12. In some embodiments, the spaced region 16 may be the majority of or substantially all of at least one of the guide rail 14. However, in other embodiments, it may be seen that the spaced region may form only a portion of a guide rail 14. It may also be seen that others of the guide rails 14 may not be configured with a spaced region. For example, it may be seen that according to certain embodiments such as the embodiment illustrated in
The guide rails 14 may be constructed from any material known to be useful or usable in the construction or concrete industries for formwork or scaffolding, including but not limited to timber, plywood, metal, plastic, fiberglass, precast concrete, or any other material suitable to or which may be adapted to the herein purposes, or any combination of such materials. In the exemplary embodiment, the guide rails 14 are simple protruding members which extend forwardly from the shotcrete receiving surface 12 at a distance configured to be further than the intended depth of the shotcrete application. Such forward extension distance may be constant along the length of the guide rail 14, or more commonly, may vary along the length of the guide rail 14. Generally, it will be an objective of certain embodiments described herein that the forward extension difference in each area of the guide rail 14 will be more distant that the intended depth of shotcrete application of at the local region of the shotcrete receiving surface 12 proximal to that area of the guide rail 14, such that in the case of guide rails 14 configured with a spaced region 16, the spaced region 16 of the guide rail 14 does not occlude the creation of a continuous surface of shotcrete at the region of the shotcrete receiving surface 12 behind the spaced region 16 such that the spaced region 16 does not become contained within the applied shotcrete. In the case of certain peripheral guide rails 14 which do not contain a spaced region 16 but instead may be used to contain the lateral application of shotcrete, it may still be desirable for the forward extension of the guide rail 14 from the shotcrete receiving surface to be further than the intended depth of the shotcrete proximal thereto, so that the guide rail 14 may still function to laterally contain the shotcrete.
Turning now to
As may be seen in
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It may also be seen that it may be desirable in certain instances that, when three or more guide rails 14 are utilized, for the lateral distance between each respective laterally adjacent guide rail 14 to be substantially identical. This may permit the use of a single screed to rod the shotcrete, rather than requiring use of multiple separately configured screeds for each respective pair of guide rails 14. It may also be seen, however, that other configurations of lateral spacing between guide rails 14 may be utilized, and that corresponding screeds 24 may be utilized to adapt to the lateral spacing of the guide rails 14. It is also envisioned that a single screed 24 may be configured so as to be utilized with different or multiple configurations of lateral spacing between guide rails 14, for example, by including a feature on the screed that permits adjustment of an engagement point on the screed or by including multiple optional engagement points. For example, it is contemplated that the screed 24 may be configured to be telescoping so as to permit adjustment of the distance between two engagement points thereupon so that the screed 24 may be utilized with many possible configurations of lateral distances between guide rails 24.
Turning now to
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The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the exemplary embodiments.
The present application is a continuation of U.S. patent application Ser. No. 17/360,186, filed on Jun. 28, 2021, now U.S. Pat. No. 11,572,700, which is a continuation of U.S. patent application Ser. No. 16/736,540, filed on Jan. 7, 2020, now U.S. Pat. No. 11,072,932, issued on Jul. 27, 2021, the entire contents of which are incorporated herein by reference.
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Number | Date | Country | |
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20230148127 A1 | May 2023 | US |
Number | Date | Country | |
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Parent | 17360186 | Jun 2021 | US |
Child | 18151316 | US | |
Parent | 16736540 | Jan 2020 | US |
Child | 17360186 | US |