US20180112421A1 - Hardenable material structure construction apparatus and method - Google Patents
Hardenable material structure construction apparatus and method Download PDFInfo
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- US20180112421A1 US20180112421A1 US15/565,155 US201615565155A US2018112421A1 US 20180112421 A1 US20180112421 A1 US 20180112421A1 US 201615565155 A US201615565155 A US 201615565155A US 2018112421 A1 US2018112421 A1 US 2018112421A1
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- extension
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- members
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G17/00—Connecting or other auxiliary members for forms, falsework structures, or shutterings
- E04G17/14—Bracing or strutting arrangements for formwalls; Devices for aligning forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/762—Exterior insulation of exterior walls
- E04B1/7629—Details of the mechanical connection of the insulation to the wall
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
- E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
- E04G11/36—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for floors, ceilings, or roofs of plane or curved surfaces end formpanels for floor shutterings
- E04G11/38—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for floors, ceilings, or roofs of plane or curved surfaces end formpanels for floor shutterings for plane ceilings of concrete
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8647—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties going through the forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2103/00—Material constitution of slabs, sheets or the like
- E04B2103/02—Material constitution of slabs, sheets or the like of ceramics, concrete or other stone-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
- E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
- E04G2011/067—Integrated forms comprising shuttering skin, bracing or strutting arrangements, workplatforms and railings
Definitions
- the invention relates generally to the field of construction and in particular to a hardenable material structure construction apparatus and method.
- the traditional method of concrete construction suffers from several disadvantages. Firstly, erecting the many wooden beams to produce a form for the concrete requires significant manual labor, which increases cost and complexity. Secondly, providing thermal insulation within the building creates thermal bridges at the ceiling/floor of each level. Although methods for thermally insulating the outer side of the concrete wall do exist, outdoor thermal insulation adds costs and complexity due to the unique challenges of outdoor construction. Additionally, the plaster securing the insulation to the outside of the concrete wall is porous and any water droplets which enter the plaster will expand when heated during the day, thereby causing an expansion of the plaster. Such an expansion will apply pressure to the facade, which can cause damage thereto.
- a third disadvantage is that a stone facade secured with plaster is only weakly secured to the concrete wall, thereby risking that the stones can fall off.
- a temporary hardenable material construction apparatus comprising: a support structure comprising a support frame, a first inner support arm extending from the support frame and a first outer support arm extending from the support frame; at least one support extension member, the at least one support extension member exhibiting a first end and a second end opposing the first end; a first enclosure member exhibiting an inner face and an outer face opposing the inner face; and a second enclosure member exhibiting an inner face and an outer face opposing the inner face, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined between the inner face of the first enclosure member and the inner face of the second enclosure member, wherein the first outer support arm is juxtaposed with the outer face of the first enclosure member, wherein the first inner support arm is juxtaposed with the outer face of the second enclosure member, wherein the at least one support extension member extends through the first enclosure member
- the support structure further comprises a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the first outer support arm being secured to the first extension arm and the extension of the first inner support arm from the support frame responsive to the first inner support arm being secured to the first extension arm.
- the support structure further comprises a second extension arm extending from the support frame, a second inner support arm secured to the second extension arm and a second outer support arm secured to the second extension arm, wherein the at least one support extension member comprises a plurality of support extension members, the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of the plurality of support extension members secured to the second inner support arm.
- the support structure further comprises a plurality of elongated strengthening arms, each exhibiting a first end and a second end opposing the first end, wherein the first end of each of the plurality of elongated strengthening arms is secured to the first inner support arm and the second end of each of the plurality of elongated strengthening arms is secured to the second inner support arm.
- the distance between the support frame and the second enclosure member is 60-120 centimeters.
- the distance between the support frame and the second enclosure member is 80-100 centimeters.
- the apparatus further comprises a plurality of free extension members, each of the plurality of free extension members exhibiting a first end and a second end opposing the first end, wherein each of the plurality of free extension members extends through the first enclosure member and the second enclosure member, and wherein the first end of each of the plurality of free extension members is not secured to the first outer support arm and the second end of each of the plurality of free extension members is not secured to the first inner support arm.
- the first inner support arm extends across the entirety of the outer face of the second enclosure member, wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member.
- the first enclosure member comprises: a plurality of strips; and a plurality of slabs, each of the plurality of slabs exhibiting a first face, a second face opposing the first face, a first side extending from the first face to the second face and a second side opposing the first side, each of the first side and the second side exhibiting a slit therealong, the slit configured to receive a respective one of the plurality of strips, wherein the first side of each of the plurality of slabs faces the second side of another of the plurality of slabs, a respective one of the plurality of strips disposed within the slit of the first side of the respective slab and within the slit of the second side of the another respective slab, and wherein each of the at least one support extension member extends through a respective one of the plurality of strips.
- the apparatus further comprises a plurality of L-shaped corner members, each of the L-shaped corner members exhibiting a first end and a second end perpendicular to the first end, the slit of each of the plurality of slabs further configured to receive one of a first end and a second end of a respective one of the plurality of L-shaped corner members, wherein the at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, the first end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a first of the pair of first enclosure members and the second end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a second of the pair of first enclosure members.
- the first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members, wherein each of the at least one support extension member extends through a respective one of the plurality of facade securing elements.
- the first enclosure member comprises: an outer layer exhibiting an inner face and an outer face opposing the inner face, the outer face of the first enclosure member comprising the outer face of the outer layer; and an insulation layer exhibiting an inner face and an outer face opposing the inner face, the inner face of the insulation layer facing the inner face of the second enclosure member, the outer face of the insulation layer facing the inner face of the outer layer.
- the outer face of the insulation layer is in direct contact with the inner face of the outer layer.
- the apparatus further comprises: a grid assembly disposed within the defined space; at least one securing member, each of the at least one securing members disposed on a respective one of the at least one support extension member and juxtaposed with the insulation layer to secure the insulation layer to the outer layer; and wherein the grid assembly is secured to the at least one extension member so as to separate the grid assembly from the insulation layer by at least a predetermined distance.
- a structure comprising: a plurality of extension members, each of the plurality of extension members exhibiting a first end and a second end opposing the first end; a first enclosure member exhibiting an inner face and an outer face opposing the inner face; and a second enclosure member exhibiting an inner face and an outer face opposing the inner face, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined between the inner face of the first enclosure member and the inner face of the second enclosure member, the space filled with a wall layer of hardenable material; wherein each of the plurality of extension members extends through the first enclosure member and the second enclosure member, and wherein the first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members, wherein each of the plurality of extension members extends through a respective one of the plurality of facade securing elements.
- each of the plurality of facade securing elements comprises a strip
- each of the plurality of facade members comprises a slab, each of the plurality of slabs exhibiting a first face, a second face opposing the first face, a first side extending from the first face to the second face and a second side opposing the first side, each of the first side and the second side exhibiting a slit therealong, the slit configured to receive a respective one of the plurality of strips
- the first side of each of the plurality of slabs faces the second side of another of the plurality of slabs, a respective one of the plurality of strips disposed within the slit of the first side of the respective slab and within the slit of the second side of the another respective slab, each of the plurality of extension members extending through a respective one of the plurality of strips.
- the structure further comprises a plurality of L-shaped corner members, each of the L-shaped corner members exhibiting a first end and a second end perpendicular to the first end, the slit of each of the plurality of slabs further configured to receive one of a first end and a second end of a respective one of the plurality of L-shaped corner members, wherein the at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, the first end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a first of the pair of first enclosure members and the second end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a second of the pair of first enclosure members.
- the first enclosure member comprises: an outer layer exhibiting an inner face and an outer face opposing the inner face, the outer face of the first enclosure member comprising the outer face of the outer layer, the outer layer comprising the plurality of facade members and the plurality of facade securing elements; and an insulation layer exhibiting an inner face and an outer face opposing the inner face, the inner face of the insulation layer facing the inner face of the second enclosure member, the outer face of the insulation layer facing the inner face of the outer layer.
- the outer face of the insulation layer is in direct contact with the inner face of the outer layer.
- the structure further comprises: a grid assembly disposed within the hardenable material; a plurality of securing members, each of the plurality of securing members disposed on a respective one of the plurality of extension members and juxtaposed with the insulation layer to secure the insulation layer to the outer layer; and wherein the grid assembly is secured to one of the plurality of extension members so as to separate the grid assembly from the insulation layer by at least a predetermined distance.
- the structure further comprises: a ceiling panel positioned over the second enclosure member; and a ceiling layer of hardenable material disposed on the ceiling panel, the insulation layer of the first enclosure member rising above the ceiling layer of hardenable material.
- a hardenable material construction method comprising: juxtaposing an outer face of a first enclosure member to a first outer support arm, the first outer support arm extending from a support frame; securing a first end of at least one support extension member to the first outer support arm; juxtaposing a first inner support arm to an outer face of a second enclosure member, the first inner support arm extending from a support frame; securing a second end of the at least one support extension member to the first inner support arm; and subsequent to the securing the at least one support extension member to the first inner support arm, placing hardenable material into the space defined between an inner face of the first enclosure member and an inner face of the second enclosure member, the inner face of the first enclosure member opposing the outer face of the first enclosure member and the inner face of the second enclosure member opposing the outer face of the second enclosure member, wherein the secured at least one support extension member extends through the first enclosure member and the second enclosure member.
- the method further comprises, prior to the placing: securing the first outer support arm to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the securing; and securing the first inner support arm to the first extension arm, the extension of the first inner support arm from the support frame responsive to the securing.
- the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to the placing: securing a second outer support arm to a second extension arm extending from the support frame; and securing a second inner support arm to the second extension arm, wherein the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of the plurality of support extension members secured to the second inner support arm.
- the method further comprises, prior to the placing: securing a first end of each of a plurality of elongated strengthening arms to the first inner support arm; and securing a second end of each of the plurality of elongated strengthening arms to the support frame.
- the distance between the support frame and the second enclosure member is 60-120 centimeters.
- the distance between the support frame and the second enclosure member is 80-100 centimeters.
- the method further comprises, prior to the placing, extending a plurality of free extension members through the first enclosure member and the second enclosure member, wherein the extended free extension members are not secured to the first inner support arm or to the first outer support arm.
- the first inner support arm extends across the entirety of the outer face of the second enclosure member, and wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member.
- the method further comprises: a) positioning a first side of each of a plurality of slabs to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof, the first side and second side of each of the plurality of slabs exhibiting a slit configured to receive a respective one of a plurality of strips; b) disposing a respective one of the plurality of strips within the slit of the first side of each of the plurality of slabs and the slit of the second side of the respective another slab; and c) inserting each of the at least on support extension member through a respective one of the plurality of strips, wherein the first enclosure member is formed responsive to steps a-b.
- the method further comprises disposing each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, within the slit of the first side of a first of the plurality of slabs and within the slit of the first side of a second of the plurality of slabs.
- the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to the placing, inserting each of the plurality of support extension members through a respective one of a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of a plurality of facade members, wherein the first enclosure member comprises the plurality of facade members.
- the method further comprises, prior to the placing: d) positioning an outer face of an insulation layer to face an inner face of an outer layer so as to form the first enclosure member, wherein the outer layer exhibits an outer face opposing the inner face thereof, the outer face of the first enclosure member comprising the outer face of the outer layer, and wherein the insulation layer exhibits an inner face opposing the outer face thereof, the inner face of the first enclosure member comprising the inner face of the insulation layer.
- step d comprises positioning the outer face of the insulation layer to be in direct contact with the inner face of the outer layer.
- the method further comprises, prior to the placing: disposing a grid assembly within the space defined between the first enclosure member and the second enclosure member; securing the insulation layer to the outer layer with a plurality of securing members, each of the plurality of securing members disposed on a respective one of the plurality of extension members; and securing the grid assembly to one of the plurality of extension members so as to separate the grid assembly from the insulation layer by at least a predetermined distance.
- FIGS. 1A-1B illustrate various high level views of a temporary hardenable material construction apparatus comprising freestandable support frames, according to certain embodiments
- FIG. 1C illustrates a high level perspective view of the temporary hardenable material construction apparatus of FIGS. 1A-1B further comprising hardenable material, according to certain embodiments;
- FIG. 1D illustrates a high level perspective view of a wall of the hardenable material of FIG. 1C , without the freestandable support frames of FIGS. 1A-1B , according to certain embodiments;
- FIGS. 2A-2B illustrate various high level views of an enclosure member comprising a plurality of slitted slabs and a plurality of strips disposed therewithin, according to certain embodiments;
- FIG. 2C illustrates a high level view of a slab of FIGS. 2A-2B , according to certain embodiments
- FIG. 2D illustrates a high level view of a strip of FIGS. 2A-2B , according to certain embodiments
- FIG. 2E illustrates a high level view of a temporary hardenable material construction apparatus comprising the enclosure member of FIGS. 2A-2B , according to certain embodiments;
- FIG. 2F illustrates a high level view of the temporary hardenable material construction apparatus of FIG. 2E , further comprising an insulation layer, according to certain embodiments;
- FIG. 2G illustrates a high level view of a portion of the temporary hardenable material construction apparatus of FIG. 2E , according to certain embodiments
- FIG. 2H illustrates a high level view of an L-shaped corner member, according to certain embodiments.
- FIGS. 3A-3D illustrate various high level views of a temporary hardenable material construction apparatus further comprising a pair of grid assemblies and a double layer enclosure member, according to certain embodiments;
- FIG. 4 illustrates a high level schematic top view of a temporary hardenable material construction apparatus comprising a spiral staircase, according to certain embodiments
- FIGS. 5A-5E illustrate various high level views of a temporary hardenable material construction apparatus comprising a ceiling panel, according to certain embodiments
- FIG. 5G illustrates a high level perspective view of a freestandable support frame configured with separate upper and lower sections, according to certain embodiments
- FIGS. 6A-6C illustrate various high level flow charts of a first hardenable material construction method, according to certain embodiments
- FIGS. 7A-7I illustrates various high level views of various stages of construction using a temporary hardenable material construction apparatus comprising support structures, according to certain embodiments.
- Temporary hardenable material construction apparatus 10 comprises: a plurality of freestandable support frames 20 , each exhibiting a first face 22 , a second face 24 opposing first face 22 , a plurality of receiving members 25 (not shown) extending across first face 22 , a base portion 26 , a top portion 27 opposing base portion 26 , a first side 28 and a second side 29 opposing first side 28 ; a plurality of freestandable support frames 30 , each exhibiting a first face 32 , a second face 34 opposing first face 32 , a plurality of receiving members 35 extending across first face 32 , a base portion 36 , a top portion 37 opposing base portion 36 , a first side 38 and a second side 39 opposing first side 38 ; a plurality of extension members 40 , each exhibiting a first end 42 and a second end 44 opposing first end 42 ; an enclosure member 50 , exhibiting an inner face 52 and an outer face 54 opposing inner face 52 ; and an enclosure member 60 ,
- each freestandable support frame 20 and 30 is constituted of any of, or a combination of, wood, plastic, metal or other polymers such as PVC and polycarbonate.
- freestandable support frames 20 and 30 are each reusable frames.
- Receiving members 25 , 35 of each respective freestandable support frame 20 , 30 are illustrated as extending horizontally across respective first face 22 , 32 thereof, however this is not meant to be limiting in any way.
- receiving members 25 , 35 extend vertically across the respective first face 22 , 32 , without exceeding the scope.
- receiving members 25 , 35 of each respective freestandable support frame 20 , 30 are provided as a single board covering the respective first face 22 , 32 , without exceeding the scope.
- First side 28 and second side 29 of each freestandable support frame 20 extends from first face 22 to second face 24 and from base portion 26 to top portion 27 .
- first sides 28 and second sides 29 are each open, i.e. a person can walk therethrough.
- base portion 26 of each freestandable support frame 20 is a generally flat and closed surface.
- the distance between first face 22 and second face 24 of each freestandable support frame 20 is about 120 centimeters.
- the distance between first face 22 and second face 24 is arranged such that two people can both work side by side within a single freestandable support frame 20 .
- the distance between first side 28 and second side 29 of each freestandable support frame 20 is about 60 centimeters.
- First side 38 and second side 39 of each freestandable support frame 30 extends from first face 32 to second face 34 and from base portion 36 to top portion 37 .
- the distance between first face 32 and second face 34 of each freestandable support frame 30 is at least 60 centimeters, optionally about 60 centimeters.
- the distance between first side 38 and second side 39 of each freestandable support frame 30 is at least 120 centimeter, optionally about 120 centimeters.
- the distance between base portion 26 and top portion 27 , and the distance between base portion 36 and top portion 37 is at least 2 meters, optionally at least 2.7 meters, so as to allow the construction of a building wall.
- each of first faces 22 and 32 , second faces 24 and 34 , base portions 26 and 36 , top portions 27 and 37 , first sides 28 and 28 , and second sides 29 and 39 are generally rectangular.
- each extension member 40 exhibits a plurality of grooves.
- Enclosure member 50 is positioned in parallel with enclosure member 60 such that a space 70 is defined between inner face 52 of enclosure member 50 and inner face 62 of enclosure member 60 .
- inner face 52 is defined as the face of enclosure member 50 which faces, and defines, space 70 and outer face 54 is defined as the face of enclosure member 50 which faces away from space 70 .
- inner face 62 is defined as the face of enclosure member 60 which faces, and defines, space 70 and outer face 64 is defined as the face of enclosure member 60 which faces away from space 70 .
- a hardenable material is arranged to be poured into space 70 .
- First face 22 of each freestandable support frame 20 is juxtaposed with outer face 54 of enclosure member 50 and in one embodiment is flush therewith. As illustrated, first face 22 of each freestandable support frame 20 is substantially completely covered by outer face 54 of enclosure member 50 . In one embodiment, as illustrated, first face 22 is rectangular shaped, with the sides of first face 22 which are defined by first side 28 and second side 29 being longer than the sides of first face 22 which are defined by base portion 26 and top portion 27 . First side 28 of each freestandable support frame 20 faces second side 29 of an adjacently positioned freestandable support frame 20 so as to form a row of freestandable support frames 20 . In one embodiment, each freestandable support frame 20 is secured to an adjacent freestandable support frame 20 .
- Each extension member 40 extends through enclosure member 50 , space 70 and enclosure member 60 such that first end 42 of each extension member 40 extends past outer face 54 of enclosure member 50 and second end 44 of each extension member 40 extends past outer face 64 of enclosure member 60 . Additionally, first end 42 of each extension member 40 is secured to a receiving member 25 of a respective one of freestandable support frames 20 . In one embodiment, where freestandable support frames 20 are constituted of wood or plastic, first end 42 extends through the respective receiving member 25 and is secured thereto on one or both sides thereof. In another embodiment, where freestandable support frames 20 are constituted of metal, first end 42 is welded to the respective receiving member 25 .
- a steel grid assembly may be disposed within space 70 .
- water and sanitation pipes and electric wiring may be disposed within space 70 prior to pouring the hardenable material described below.
- a hardenable material 80 is poured into space 70 .
- hardenable material 80 comprises concrete.
- hardenable material 80 comprises any fluidic material which hardens.
- FIGS. 1A-1C are illustrated where space 70 is open at the ends of enclosure members 50 , 60 , however temporary hardenable material construction apparatus 10 is particularly contemplated as comprising means for containing hardenable material 80 within space 70 .
- four perpendicular spaces 70 are constructed thereby creating a single enclosed space for hardenable material 80 .
- the ends of space 70 are covered with material to hold hardenable material 80 therein.
- a wall 90 is thus provided, comprising enclosure members 50 , 60 and hardened hardenable material 80 .
- the hardened hardenable material 80 doesn't have to be covered with additional wall sections, since enclosure members 50 , 60 are already attached thereto.
- one or both of enclosure members 50 , 60 can be removed after hardenable material 80 hardens, so the hardened hardenable material 80 can be covered with other materials or left exposed.
- Temporary hardenable material construction apparatus 10 has been describe and illustrated as comprising one or more freestandable support frames 20 and one or more freestandable support frames 30 , however this is not meant to be limiting in any way.
- freestandable support frames 30 are not provided and extension members 40 are secured to freestandable support frames 20 .
- freestandable support frames 20 are not provided and extension members 40 are secured to freestandable support frames 30 .
- enclosure member 50 comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members.
- First end 42 of each extension member 40 extends through a respective one of the plurality of facade securing elements.
- the facade members are members which form a facade, such as stones.
- the facade members can exhibit any shape and dimensions which are desired.
- the perimeter of each facade member i.e. the sides thereof, exhibit a plurality of insertion holes, each the insertion holes containing a respective one of the plurality of facade securing elements.
- the facade securing elements are each designed to exhibit an opening to receive therethrough an extension member 40 .
- Enclosure member 50 is formed by positioning the facade members along a single plane, each facade member optionally secured to an adjacent facade member with appropriate material, such as mortar.
- FIG. 2H illustrates a high level perspective view of an L-shaped corner member 210 .
- FIG. 2I illustrates a high level perspective view of a pair of perpendicularly positioned enclosure members 100 secured to each other with a plurality of L-shaped corner members 210 .
- FIGS. 2A-21 will be described together.
- a first slab 110 is positioned and a strip 120 is disposed within slit 130 of first side 113 thereof. At least two extension members 40 are then inserted through respective holes 140 of the disposed strip 120 . An additional slab 110 is then position on top of the first slab 110 such that the disposed strip 120 is additionally disposed within second side 114 of the additional slab 110 , the separation of the adjacent slabs 110 being maintained by the inserted extension members 40 .
- a predetermined number of slabs 110 are left out of enclosure member 100 .
- a frame is inserted which extends through space 70 thereby not allowing hardenable material to enter the space surrounded by the inserted frame.
- first and second ends 42 , 44 of each extension member 40 is sawed off.
- the space between each adjacent pair of slabs 110 is filled with a filling material.
- an insulation layer 150 is further provided, juxtaposed with second faces 112 of slabs 110 , as will be described below in relation to temporary hardenable material construction apparatus 300 .
- each L-shaped corner member 210 exhibits a first half 212 and a second half 214 , second half 214 being perpendicular to first half 212 .
- First half 212 of each L-shaped corner member 210 is disposed within respective slits 130 of a first of the pair of perpendicularly positioned enclosure members 100 and second half 214 of each L-shaped corner member 210 is disposed within respective slits 130 of the second of the pair of perpendicularly positioned enclosure members 100 .
- L-shaped corner members 210 are each formed as a single piece, i.e. not two separate pieces which are welded or screwed together. Therefore, when hardenable material is poured into space 70 defined by both enclosure members 100 , L-shaped corner members 210 secure enclosure members 100 to each other so as not separate responsive to the pressure applied by the poured hardenable material.
- slabs 110 are provided with slits within first face 111 , the slits being of appropriate shape and size such that a strip 120 , or a portion thereof, can be inserted therein and secured to slab 110 .
- Extension members 40 are secured to strips 120 , optionally by welding. Since the slits are within first face 111 , thereby facing space 70 , and not between adjacent slabs 110 , extension members 40 do not interfere with the placement of slabs 110 and the rows of slabs 110 can be flush with each other.
- FIG. 3A illustrates a perspective view of a temporary hardenable material construction apparatus 300
- FIG. 3B illustrates a side view of temporary hardenable material construction apparatus 300 , FIGS. 3A-3B being described together.
- Temporary hardenable material construction apparatus 300 is in all respects similar to temporary hardenable material construction apparatus 10 , further comprising a pair of grid assemblies 310 and a plurality of securing members 320 . Additionally, enclosure member 50 is replaced with an enclosure member 330 .
- Enclosure member 330 comprises: an outer layer 340 exhibiting an inner face 342 and an outer face 344 opposing inner face 342 ; and an insulation layer 350 exhibiting an inner face 352 and an outer face 354 .
- outer face 354 of insulation layer 350 is in direct contact with inner face 342 of outer layer 340 , i.e. there is no plaster between insulation layer 350 and outer layer 340 .
- the condensation does not remain between insulation layer 350 and outer layer 340 and thus will not expand during the day and cause damage and deformations of outer layer 340 .
- Each securing member 320 is attached to a respective one of extension members 40 , preferably screwed thereon, and disposed on inner face 352 of insulation layer 350 .
- Securing members 320 are arranged to press insulation layer 350 against outer layer 340 to secure insulation layer 350 to outer layer 340 to further maintain the predetermined distance between insulation layer 350 and the adjacent grid assembly 310 .
- an additional securing member is attached to each extension member 40 and disposed on inner face 62 of enclosure member 60 to secure enclosure member 60 to freestandable support frames 30 while maintaining smooth contact therewith.
- grid assemblies 310 are welded to at least some of extension members 40 at the predetermined distance from the respective one of enclosure members 330 , 60 .
- each grid assembly 310 which may be positioned to be substantially parallel to enclosure members 60 and 330 and substantially perpendicular to extension members 40 , may be welded to a plurality of extension members 40 .
- each grid assembly 310 may be welded to the extension members 40 by a weld formation to define a plurality of rectilinear hoops H.
- Each hoop H is typically defined by eight welds: (1) weld j at the junction of a first extension member 40 and a first vertical bar of grid assembly 310 , (2) weld k at the junction of the first extension member and a second vertical bar of grid assembly 310 which is transversally spaced from the first extension member, (3) weld 1 at the junction of a second extension member located directly below the first extension member and the first vertical bar, (4) weld m at the junction of the second extension member and the second vertical bar, (5) weld j′ (not shown) at the junction of a third extension member being at the same height as, and longitudinally spaced from, the first extension member and a third vertical bar longitudinally spaced from the first vertical bar, (6) weld k′ (not shown) at the junction of the third extension member and a fourth vertical bar transvers
- a hoop may be defined by a weld at the junction of an extension member and a horizontal bar of grid assembly 310 .
- a reinforced wall structure of superior impact resistance is produced.
- Each hoop H confines a corresponding volume of the hardened material, particularly concrete, and significantly increases the strain capacity, often as much as ten-fold.
- the hoops H act to restrain dilation of the hardened material as it is loaded in compression, and this confining action leads to increased compressive strength and strain capacity. Indeed, tests conducted by the Applicant indicated that the impact resistance of the hoop-reinforced wall structure of the present invention has an impact resistance of greater than 40% relative to prior art wall structures that are reinforced only by a grid assembly, and not by hoops.
- a prebent grid assembly 370 may be employed.
- a planar grid assembly is preferably bent at a factory by a dedicated bending machine to produce prebent grid assembly 370 , but may be also be bent in situ.
- Prebent grid assembly 370 has a rectilinear configuration with two longitudinal portions 372 and 373 and three transversal portions 376 - 378 .
- the rectilinear configuration simplifies deployment of the grid assembly in the space between the inner and outer standable support frames, without need of bracing or the like to maintain the grid assembly in an upright position by virtue of the stable rectilinear configuration.
- the first longitudinal portion 372 which is the longest longitudinal portion and the first transversal portion 376 which is the longest transversal portion are adjacent and substantially perpendicular to each other.
- first longitudinal portion 372 has a length of 120 cm and first transversal portion 376 has a length of 15 cm.
- prebent grid assembly 370 advantageously allows the reinforced wall structure to have an increased number of hoops for a given wall thickness. Extension members are welded to portions of prebent grid assembly 370 to define each hoop.
- Prebent grid assembly 370 is positioned in the space between the inner and outer standable support frames, and of course additional longitudinally spaced prebent grid assemblies may also be positioned in the space between the inner and outer standable support frames.
- a three-dimensional hoop K is typically defined by eight welds: (1) weld s at the junction of first extension member 40 A and first longitudinal portion 372 of a first bent bar of the grid assembly, (2) weld t at the junction of first extension member 40 A and second longitudinal portion 373 of the first bent bar, (3) weld s′ (not shown) at the junction of a second extension member located directly below first extension member 40 A and first longitudinal portion 372 of a second bent bar located below the first bent bar, (4) weld t′ at the junction of the second extension member and second longitudinal portion 373 of the second vertical bar, (5) weld u at the junction of third extension member 40 C being at the same height as, and longitudinally spaced from, first extension member 40 A and first longitudinal portion 372 of a first bent bar, (6) weld v at the junction of third extension member 40 C and second longitudinal portion 373 of the first bent bar, (7) weld u′ (not shown) at the junction of a fourth extension member located directly below third extension
- An additional hoop L of smaller dimensions may be formed from first extension member 40 A between welds s and t, first transversal portion 376 , first longitudinal portion 372 between first transversal portion 376 and weld s, and second longitudinal portion 373 between first transversal portion 376 and weld t.
- a wall structure having such a high impact resistance is able to remain intact after being impacted by a projectile having a speed of up to 2500 kilometer/hr.
- FIG. 4 illustrates a high level schematic diagram of a high level top view of a portion of a temporary hardenable material construction apparatus 400 .
- Temporary hardenable material construction apparatus 400 comprises a pair of temporary hardenable material construction apparatuses 300 positioned perpendicularly to each other.
- Temporary hardenable material construction apparatus 400 further comprises a spiral staircase 410 at a corner 420 where perpendicularly positioned temporary hardenable material construction apparatuses 300 meet.
- spiral staircase 410 positioned within the empty space of corner 420 .
- Spiral staircase 410 is arranged to rise to the height of top portions 27 of freestandable support frames 20 so that a second level of freestandable support frames 20 , which are disposed on top of the first level of freestandable support frames 20 , is easily accessible. If additional levels of freestandable support frames 20 are provided, as will be described further below, spiral staircase 410 is arranged to rise to the highest level of freestandable support frames 20 .
- only a portion of each temporary hardenable material construction apparatus 300 is illustrated. Additionally, for simplicity, grid assemblies 310 and securing members 320 are not illustrated.
- FIG. 5A illustrates a high level perspective view of a portion of a temporary hardenable material construction apparatus 500 .
- FIG. 5B illustrates a high level side view of the portion of temporary hardenable material construction apparatus 500 of FIG. 5A .
- FIG. 5C illustrates a high level perspective view of temporary hardenable material construction apparatus 500 .
- FIG. 5D illustrates a high level side view of temporary hardenable material construction apparatus 500 .
- FIG. 5E illustrates a high level top view of temporary hardenable material construction apparatus 500 .
- FIG. 5F illustrates a high level perspective view of a temporary hardenable material construction apparatus 600 .
- FIGS. 5A-5F are described together.
- Temporary hardenable material construction apparatus 500 is in all respects similar to temporary hardenable material construction apparatus 300 with the addition of: a plurality of freestandable support frames 510 ; a ceiling panel 520 exhibiting a first face 521 , a second face 522 opposing first face 521 , a first side 523 extending from first face 521 to second face 522 , a second side 524 opposing first side 523 and extending from first face 521 to second face 522 , a third side 525 perpendicular to first side 523 and extending from first face 521 to second face 522 , and a fourth side 526 opposing third side 525 and extending from first face 521 to second face 522 ; and a plurality of hardenable material securing members 530 .
- Second face 522 of ceiling panel 520 is disposed on top portions 37 of freestandable support frames 30 and on enclosure member 60 . Particularly, first side 523 of ceiling panel 520 meets the plane defined by inner face 62 of enclosure member 60 , ceiling panel 520 extending away from freestandable support frames 30 . As illustrated in FIGS. 5C and 5D , ceiling panel 520 is disposed on four rows of freestandable support frames 30 .
- Each of a first set of hardenable material securing members 530 extends vertically from within ceiling panel 520 to a point above first face 521 . In one embodiment, each hardenable material support member 530 extends about 12 centimeters above first face 521 .
- each hardenable material support member 530 is 6-8 millimeters thick. In one embodiment, hardenable material securing members 530 are spaced apart from each other at distances of about 60 centimeters. In another embodiment, each hardenable material support member 530 comprises a screw. Similarly, each of a second set of hardenable material securing members 530 extends horizontally from within enclosure member 60 to a point within space 70 , displaced from inner face 62 of enclosure member 60 . In one embodiment, wooden beams, and optionally an additional wooden panel, are disposed between ceiling panel 520 and top portions 37 of freestandable support frames 30 .
- a spiral staircase 410 is positioned at each corner of the rows of freestandable support frames 20 such that freestandable support frames 510 are easily accessible.
- Hardenable material 80 is poured onto ceiling panel 520 .
- Hardenable material 80 which as described above is a fluid material, such as concrete, spills over first, second, third and fourth sides 523 , 524 , 525 , 526 of ceiling panel 520 into space 70 formed between the four second enclosure members 60 and four enclosure members 330 .
- four walls and a ceiling are formed as a single block of hardenable material 80 , which gradually hardens.
- Hardenable material securing members 530 are arranged to secure ceiling panel 520 and each of enclosure members 60 to hardenable material 80 after hardening.
- the drywall panels are directly attached to the hardened hardenable material, without the use of plaster.
- temporary hardenable material construction apparatus 600 of FIG. 5F represents temporary hardenable material construction apparatus 500 after hardenable material 80 is poured.
- temporary hardenable material construction apparatus 600 is in all respects similar to temporary hardenable material construction apparatus 500 , with the exception that freestandable support frames 30 are replaced with a plurality of freestandable support frames 610 . Additionally, an enclosure member 620 is provided.
- Freestandable support frames 610 are in all respects similar to freestandable support frames 30 , with the exception that base portions 36 of freestandable support frames 610 are positioned on top of hardenable material 80 , over ceiling panel 520 and over the location of the previously positioned freestandable support frames 30 .
- Enclosure member 620 is in all respects similar to enclosure member 60 , with the exception that enclosure member 620 is positioned on top of hardenable material 80 , over ceiling panel 520 and over enclosure member 60 .
- first face 32 of each freestandable support frame 30 is juxtaposed with outer face 64 of enclosure member 620 .
- a space 70 is defined between inner face 52 of enclosure member 330 and inner face 62 of enclosure member 620 .
- a ceiling panel (not shown) can be positioned on top of freestandable support frames 610 and hardenable material 80 can be poured thereon, as described above in relation to temporary hardenable material construction apparatus 500 .
- extension members 40 extend through enclosure member 330 and enclosure member 620 and are secured to freestandable support frames 510 and freestandable support frames 610 .
- an inner freestandable support frame 630 is used to support ceiling panel 520 .
- Temporary hardenable material construction apparatus 500 and 600 are applicable to freestandable support frame 630 , the other aspects thereof applying with the exception of freestandable support frame 30 , mutatis mutandis.
- inner freestandable support frame 630 is configured with separate upper section 632 and lower section 634 , which may be identical, albeit oppositely oriented.
- upper section 632 and lower section 634 which may be identical, albeit oppositely oriented.
- a corresponding elongated connector 637 which may have a uniform width and be carefully positioned so as not to protrude into the space within which the hardenable material is to be poured.
- Inner freestandable support frame 630 generally, but not necessarily, has the same dimensions as freestandable support frame 30 .
- a rectilinear inner freestandable support frame 630 has a height of 270 cm, a longitudinal dimension of 120 cm and a transversal dimension of 60 cm. This height is achievable by providing a void area of 30 cm between upper section 632 and lower section 634 and by releasably securing connector 637 having a length of 30 cm to the upright of both upper section 632 and lower section 634 .
- an insert 639 is received within the void area in such a way so as to contact and be in force transmitting relation with both upper section 632 and lower section 634 . Insert 639 is releasably connected to connector 637 .
- inner freestandable support frame 630 may be configured with any other number of interconnectable sections.
- freestandable support frames 20 , 30 , 510 , 610 and 630 this is not meant to be limiting in any way.
- freestandable support frames 20 , 30 , 510 and 610 can be replaced with support frames which are not freestandable without exceeding the scope.
- a first freestandable support frame is juxtaposed with an outer face of the first enclosure member of stage 1000 or the outer face of the second enclosure member of stage 1000 .
- the outer face of the first enclosure member opposes the inner face of the first enclosure member.
- the outer face of the second enclosure member opposes the inner face of the second enclosure member.
- First freestandable support frame extends from a first face to a second face, the first face thereof juxtaposed with the outer face of the first enclosure member.
- the distance between the first face and the second face of the first freestandable support frame is about 120 centimeters.
- a plurality of first freestandable support frames are each juxtaposed with the outer face of the first enclosure member, or the outer face the second enclosure member, the plurality of first freestandable support frames arranged in a row.
- the first freestandable support frame exhibits an indentation in the first face thereof, the indentation arranged to receive a protruding portion of the first enclosure member of stage 1000 .
- a second freestandable support frame is juxtaposed with an outer face of the second enclosure member of stage 1000 , the outer face of the second enclosure member opposing the inner face of the second enclosure member.
- the first freestandable support frame of stage 1010 is juxtaposed with the outer face of the first enclosure member of stage 1000 .
- a plurality of second freestandable support frames are each juxtaposed with the outer face of the second enclosure member, the plurality of second freestandable support frames arranged in a row.
- At least one extension member is inserted through the first enclosure member and the second enclosure member such that a first end of the at least one extension member extends past the outer face of the first enclosure member of stage 1000 or a second end of the at least one extension member, opposing the first end thereof, extends past the outer face of the second enclosure member of stage 1000 .
- the at least one extension member of stage 1030 is secured to the first freestandable support frame of stage 1010 .
- a plurality of extension members are each secured to a respective one of a plurality of first freestandable support frames.
- the second end of the at least one extension member is secured to the second freestandable support frame of optional stage 1020 .
- a plurality of extension members are each secured to a respective one of a plurality of second freestandable support frames.
- stage 1060 subsequent to the securing the at least one extension member to the first and second freestandable support frame of stages 1040 - 1050 , hardenable material is poured into the space defined between the first enclosure member and the second enclosure member of stage 1000 .
- an outer face of an insulation layer is positioned to face an inner face of an outer layer so as to form the first enclosure member of stage 1000 .
- the outer layer exhibits an outer face opposing the inner face thereof, an outer face of the first enclosure member of stage 1000 , opposing the inner face thereof, comprising the outer face of the outer layer.
- the insulation layer exhibits an inner face opposing the outer face thereof, the inner face of the first enclosure member of stage 1000 comprising the inner face of the insulation layer.
- the outer face of the insulation layer is positioned to be in direct contact with the inner face of the outer layer. Particularly, no plaster is disposed between the insulation layer and the outer layer.
- a grid assembly is disposed within the defined space of stage 1000 . Additionally, the grid assembly is secured to one of a plurality of the extension members of stage 1030 so as to separate the grid assembly from the insulation layer of optional stage 1070 by at least a predetermined distance. In optional stage 1090 , the insulation layer is secured to the outer layer with a plurality of securing members, each of the plurality of securing members disposed on a respective one of a plurality of the extension members of stage 1030 .
- FIG. 6B illustrates a high level flow chart of optional stages of forming the first enclosure of stage 1000 of FIG. 6A .
- stage 2000 a first side of each of a plurality of slabs is positioned to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof.
- the first side and second side of each of the plurality of slabs exhibit a slit configured to receive a respective one of a plurality of strips.
- a respective one of the plurality of strips of stage 2000 is disposed within the slit of the first side of each of the plurality of slabs of stage 2000 and the slit of the second side of the respective another slab.
- each of a plurality of the extension members of stage 1030 is inserted through a respective one of a plurality of facade securing elements, the facade securing elements each secured to one of a plurality of facade members.
- each facade member comprises a slab of stage 2000 and each facade securing element comprises a strip of stage 2010 .
- the insertion through the first enclosure member of stage 1030 is responsive to the insertion through the plurality of facade securing elements.
- each of a plurality of L-shaped corner members is disposed within the slit of the first side of a first of the plurality of slabs of stage 2000 and within the slit of the first side of a second of the plurality of slabs.
- FIG. 6C illustrates a high level flow chart of further optional stages of the hardenable material construction method of stages 1000 - 1090 .
- stage 3000 prior to the pouring hardenable material of stage 1060 , a ceiling panel is positioned to be supported by an upper portion of the second freestandable support frame of stage 1020 .
- stage 3010 a third freestandable support frame is positioned on top of the first freestandable support frame.
- stage 3020 the third freestandable support frame of stage 3010 is juxtaposed with the outer face of the first enclosure member, the insulation layer of the first enclosure member of optional stage 1070 rising above the positioned ceiling panel.
- stage 3030 hardenable material is poured onto the ceiling panel, the pouring hardenable material into the space defined between the first enclosure member and the second enclosure member of stage 1060 responsive to the pouring hardenable material onto the positioned ceiling panel.
- the hardenable material spills from the ceiling panel into the defined space such that a single block of hardenable material is formed as a ceiling and walls.
- the positioned ceiling panel comprises a drywall panel with a plurality of hardenable material securing members inserted into the drywall panel such that each of the plurality of hardenable material securing members extend from within the drywall panel to a point above a face of the drywall panel.
- FIGS. 7A-7I illustrates various high level views of various stages of construction using a temporary hardenable material construction apparatus 700 , according to certain embodiments.
- FIG. 7A illustrates a high level perspective view of a support structure 710 comprising: a support frame 720 ; a pair of extension arms 730 , each exhibiting a first end 732 and a second end 734 opposing first end 732 ; a pair of inner support arms 740 ; and a pair of outer support arms 750 .
- Upper arms 760 each extend downwards in a generally vertical direction from top portion 800 at first end 762 thereof and lower arms 770 each extend upwards in a generally vertical direction from base portion 790 at first end 772 thereof such that second end 764 of each upper arm 760 faces second end 774 of each lower arm 774 , with an adjustable space 810 between them.
- First end 782 of each connection arm 780 is secured to a respective upper arm 760 and the respective second end 784 is secured to the opposing lower arm 770 .
- upper arms 760 and lower arms 770 are respectively connected to connecting arms 780 at different points thereof.
- base portion 790 is generally rectangular shaped with short opposing sides 792 and 794 and long opposing sides 796 and 798 .
- First end 772 of each lower arm 770 is secured at a respective corner of the generally rectangular shaped base portion 790 .
- top portion 800 is generally rectangular shaped with short opposing sides 802 and 804 and long opposing sides 806 and 808 .
- First end 762 of each upper arm 760 is secured at a respective corner of the generally rectangular shaped top portion 800 .
- the length of each of long sides 796 , 798 , 806 and 808 are at least 60 centimeters, optionally at least 80 centimeter and further optionally about 120 centimeters.
- the length of each of short sides 792 , 794 , 802 and 804 is at least 60 centimeters. In one particular embodiment, the length of each of short sides 792 , 794 , 802 and 804 is about 60 centimeters and the length of each of long sides 796 , 798 , 806 and 808 is about 120 centimeters. As described above in relation to freestandable support frames 20 and 30 , such dimensions allow for support frame 720 to be freestandable and further allows for two workers to simultaneously be inside support frame 720 . In one embodiment, support frame 720 is bolted into the floor.
- a first extension arm 730 extends from side 806 of top portion 800 , at first end 732 thereof, and a second extension arm 730 extends from side 808 of top portion 800 , at first end 732 thereof.
- side 806 and first extension arm 730 form a single beam and side 808 and second extension arm 730 form a single beam.
- the length of each extension arm 730 is no more than 150 centimeters such that support frame 720 can support inner support arms 740 and outer support arms 750 , as will be described below.
- a first outer support arm 750 extends downward in a generally vertical direction from second end 734 of first extension arm 730 and a second outer support arm 750 extends downward in a generally vertical direction from second end 734 of second extension arm 730 .
- a first inner support arm 740 extends downward in a generally vertical direction from a predetermined point of first extension arm 730 and a second inner support arm 740 extends downward in a generally vertical direction from a predetermined point of second extension arm 730 .
- the distance between inner support arms 740 and outer support arms 750 is denoted 820 , distance 820 being determined in accordance with the desired wall dimensions, as will be described below. In one non-limiting embodiment, distance 820 is about 30 centimeters.
- the distance between inner support arms 740 and support frame 720 is denoted 830 . In one embodiment, distance 830 is between 60-120 centimeters, optionally 80-100 centimeters. These distances 830 short enough to allow support frame 720 to support inner support arms 740 and outer support arms 750 and long enough to allow space to work and walk through.
- support structure further comprises a plurality of elongated strengthening arms 840 .
- a first set of strengthening arms 840 extend from first inner support arm 740 to support frame 720 and a second set of strengthening arms 840 extend from second inner support arm 740 to support frame 720 , thereby strengthening the connection between inner support arms 740 to support frame 720 .
- each set of strengthening arms 840 comprises a plurality of strengthening arms 840 in a ladder like structure and generally evenly spaced.
- strengthening arms 840 is positioned within support structure 710 , i.e. in the space between the pair of inner support arms 740 , such that a plurality of support structures 710 can be positioned flush against each other as illustrated in FIG. 7F .
- a first strip 120 is secured to the bottom of each outer support arm 750 .
- a plurality of support extension members 850 are provided, each exhibiting a first end 852 and a second end 854 opposing first end 852 .
- each support extension member is a bar about 8 millimeters thick.
- a first support extension member 850 extends through a respective hole 140 of first strip 120 and is secured to first outer support arm 750 at first end 852 thereof.
- a second support extension member 850 extends through a respective hole 140 of first strip 120 and is secured to second outer support arm 750 at first end 852 thereof.
- first end 852 is sharpened to allow support extension members 850 to be screwed into the respective outer support arms 750 .
- a plastic sheath (not shown) is arranged to cover each support extension member 850 to allow easier extraction of support extension members 850 from hardenable material, as will be described below.
- a plurality of free extension members 860 are provided, each exhibiting a first end 862 and a second end 864 opposing first end 862 .
- each free extension member 860 is a bar about 8 millimeters thick.
- First end 862 of each of a pair of free extension members 860 extend through a respective hole 140 of first strip 120 .
- a cap is screwed over first end 862 of each free extension member 860 so as to remain secured to first strip 120 .
- a first slab 110 is the positioned over the secured first strip 120 , with first strip 120 disposed within slit 130 of first side 113 of first slab 110 , as described above in relation to enclosure member 100 of FIGS. 2A-21 .
- a second strip 120 is disposed within slit 130 of second side 114 of first slab 110 and a pair of support extension members 850 and a pair of free extension members 860 are inserted through respective holes 140 of second strip 120 , as described above.
- Slabs 110 and strips 120 are interchangeably positioned over each other, with support extension members 850 and free extension members 860 inserted through respective holes 140 , until the uppermost strip 120 is adjacent to extension arms 730 , as illustrated in FIG. 7C .
- a panel 870 and a panel 880 are provided.
- Panel 870 exhibits an inner face 872 and an outer face 874 opposing inner face 872 .
- Panel 880 exhibits an inner face 882 and an outer face 884 opposing inner face 882 .
- panel 870 and panel 880 are each a RAPID composite wall panel commercially available from Green & Easy House Inc. of Rishon Le'tzion, Israel.
- Outer face 874 of panel 870 is positioned against slabs 110 with support extension members 850 and free extension members 860 extending therethrough such that panel 870 and slabs 110 for an enclosure member 890 , as described above in relation to insulation layer 150 .
- inner face 874 of panel 870 faces support frame 720 .
- Outer face 874 of panel 870 substantially covers all of the stacked slabs 110 and strips 120 .
- Panel 880 is positioned between panel 870 and support frame 720 such that inner face 882 of panel 880 faces inner face 872 of panel 870 with support extension members 850 and free extension members 860 extending therethrough, thereby forming an enclosure member 900 .
- the size and shape of panels 870 and 880 are generally equal.
- a space 70 is thus defined between enclosure members 890 and 900 , i.e. between inner face 872 of panel 870 and inner face 882 of panel 880 .
- first and second inner support arms 740 are positioned against outer face 884 of panel 880 with support extension members 850 extending through inner support arms 740 .
- a nut is screwed onto each support extension member 850 such that inner support arms 740 are secured to panel 880 .
- inner support arms 740 are each secured to the respective extension arm 730 .
- enclosure member 890 is juxtaposed with inner support arms 740 and enclosure member 900 is juxtaposed with outer support arms 750 .
- elongated strengthening arms 840 are secured to inner support arms 740 and support frame 720 , as described above.
- a plurality of support structures 710 with the respective slabs 110 , strips 120 , support extension members 850 , free extension members 860 , panel 870 and panel 880 , are positioned adjacent to each other such that panels 870 form a single panel and panels 880 form a single panel with space 70 defined therebetween.
- hardenable material 80 is poured into space 70 .
- inner support arm 740 and elongated strengthening arms 840 are removed.
- Support extension members are then extracted from outer support arms 750 and removed from hardenable material 80 .
- outer support arms 750 are removed.
- outer support arms 750 are removed together with extension arms 730 .
- a wall comprised of hardenable material 80 is sandwiched between panel 880 the combination of panel 870 and slabs 110 , with free extension members 860 securing slabs 110 , via strips 120 , to panel 870 .
- temporary hardenable material construction apparatus 700 allows to construct building walls without the use of cranes, or with limited use thereof, since the walls are constructed utilizing the support of support frames 720 which are inside the building. It is particularly noted that the features of temporary hardenable material construction apparatus 700 can be incorporated with the features of temporary hardenable material construction apparatuses 200 and 300 , and the appropriate features of temporary hardenable material construction apparatuses 10 , 400 , 500 and 600 , as would be clear to one skilled in the art at the time of the invention.
- strips 120 are secured to a grid assembly, such as grid assembly 310 described above, optionally by metal wires bent through a pair of holes 140 and tied to the grid assembly after being inserted through panel 870 .
- panel 880 is secured to the grid assembly, optionally by bent metal wires being inserted therethrough at at least two points and tied to the grid assembly.
- FIG. 8A illustrates a high level flow chart of a second hardenable material construction method.
- stage 4000 an outer face of a first enclosure member is juxtaposed with a first outer support arm.
- the first outer support arm extends from a support frame.
- the first outer support arm extends across the entirety of the outer face of the first enclosure member.
- the first outer support arm is secured to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the securement to the first extension arm.
- a first end of at least one support extension member is secured to the first outer support arm of stage 4000 .
- a first inner support arm is juxtaposed with an outer face of a second enclosure member.
- the first inner support arm extends from the support frame of stage 4000 .
- the first inner support arm extends across the entirety of the outer face of the second enclosure member.
- the first inner support arm is secured to a first extension arm extending from the support frame, the extension of the first inner support arm from the support frame responsive to the securement to the first extension arm.
- the distance between the support frame and the second enclosure member is 60-120 centimeters, further optionally 80-100 centimeters.
- a second end of the at least one support extension member of stage 4010 is secured to the first inner support arm of stage 4020 .
- stage 4040 subsequent to the securing of stages 4010 and 4030 , hardenable material is placed into the space defined between an inner face of the first enclosure member of stage 4000 and the inner face of the first enclosure member of stage 4020 .
- the secured at least one support extension member of stages 4010 and 4030 extends through the first and second enclosure member.
- a second outer support arm and a second inner support arm are each secured to a second extension member which extends from the support frame of stage 4000 .
- the at least one support extension member comprises a plurality of support extension members. A first end of a first support extension member is secured to the first outer support arm of stage 4000 . A first end of a second support extension member is secured to the second outer support arm. A second end of the first support extension member is secured to the first inner support arm of stage 4020 . A second end of the second support extension member is secured to the second inner support arm.
- elongated strengthening arms are each secured between the first inner support arm of stage 4020 and the support frame of stage 4000 .
- a plurality of free extension member are extended through the first enclosure member of stage 4000 and the second enclosure member of stage 4020 .
- the free extension members are not secured to either the first outer support arm of stage 4000 or the first inner support arm of stage 4020 .
- an insulation layer is secured to an outer layer of the first enclosure member of stage 4000 , with securing members each disposed on a respective free extension member of optional stage 4070 .
- a grid assembly is disposed within the defined space of stage 4040 . The grid assembly is further secured to a free extension member of optional stage 4070 so as to separate the grid assembly from the insulation layer of optional stage 4080 by at least a predetermined distance.
- FIG. 8B illustrates a high level flow chart of optional stages of forming the first enclosure of stage 4000 of FIG. 8A .
- stage 5000 a first side of each of a plurality of slabs is positioned to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof.
- the first side and second side of each of the plurality of slabs exhibit a slit configured to receive a respective one of a plurality of strips.
- a respective one of the plurality of strips of stage 5000 is disposed within the slit of the first side of each of the plurality of slabs of stage 5000 and the slit of the second side of the respective another slab.
- the at least one support extension member of stage 4010 is inserted through a respective one of a plurality of facade securing elements, the facade securing elements each secured to one of a plurality of facade members.
- each facade member comprises a slab of stage 5000 and each facade securing element comprises a strip of stage 5010 .
- the extension of the at least one support extension member through the first enclosure member of stage 4040 is responsive to the insertion through the respective facade securing element.
Abstract
A construction apparatus constituted of: a support structure comprising a support frame, a first inner support arm extending from the support frame and a first outer support arm extending from the support frame; a support extension member; a first enclosure member; and a second enclosure member, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined therebetween, wherein the first outer support arm is juxtaposed with the outer face of the first enclosure member, wherein the first inner support arm is juxtaposed with the outer face of the second enclosure member, wherein the support extension member extends through the first enclosure member and the second enclosure member, and wherein the first end of the support extension member is secured to the first outer support arm and the second end of the support extension member is secured to the first inner support arm.
Description
- The present application claims priority from: U.S. patent application Ser. No. 14/682,133, filed Apr. 9, 2015 and titled “HARDENABLE MATERIAL STRUCTURE CONSTRUCTION APPARATUS AND METHOD”; Israeli patent application S/N 239991, filed Jul. 16, 2015 and titled “WALL CONSTRUCTION SYSTEM AND METHOD”; and U.S. provisional patent application Ser. 62/259,693, filed Nov. 25, 2015 and titled “HARDENABLE MATERIAL STRUCTURE CONSTRUCTION APPARATUS AND METHOD”. The entire contents of each of the above are incorporated herein by reference.
- The invention relates generally to the field of construction and in particular to a hardenable material structure construction apparatus and method.
- Concrete has been used for construction since ancient times and in recent years several different types of hardenable material, i.e. liquid material which harden into a solid material, which provide similar or superior properties to concrete, have been developed. Traditionally, in order to construct a concrete wall a metal grid is erected and a form is built for the concrete with a large number of wooden beams on both sides, the wooden beams connected to each other and otherwise reinforced so as not to buckle when the concrete is poured. Concrete is then poured between the erected wooden beams and left to harden. After the concrete hardens, the wooden beams are removed thereby exposing the concrete wall. The inside of the concrete wall is then typically insulated with thermal insulation material and a cinder block wall is erected over the thermal insulation. Additionally, a facade is built on the outer side of the concrete wall, generally secured to the concrete wall with plaster.
- Unfortunately, the traditional method of concrete construction suffers from several disadvantages. Firstly, erecting the many wooden beams to produce a form for the concrete requires significant manual labor, which increases cost and complexity. Secondly, providing thermal insulation within the building creates thermal bridges at the ceiling/floor of each level. Although methods for thermally insulating the outer side of the concrete wall do exist, outdoor thermal insulation adds costs and complexity due to the unique challenges of outdoor construction. Additionally, the plaster securing the insulation to the outside of the concrete wall is porous and any water droplets which enter the plaster will expand when heated during the day, thereby causing an expansion of the plaster. Such an expansion will apply pressure to the facade, which can cause damage thereto. In the event that the facade is made of stone, the stones can fall off the building, which can cause damage and bodily harm. The same disadvantage applies for a facade directly secured to the concrete wall with plaster. A third disadvantage is that a stone facade secured with plaster is only weakly secured to the concrete wall, thereby risking that the stones can fall off.
- Although many premade concrete forms have been developed to reduce the amount of wooden beam construction on site, the other disadvantages still remain. Additionally, although wooden beam construction is reduced, each concrete form type presents new challenges which increase cost and complexity.
- It is therefore an object of the present disclosure to overcome at least part of the disadvantages of the prior art.
- Accordingly, it is a principal object of the present invention to overcome disadvantages of prior art methods and arrangements of hardenable material construction. This is provided in one embodiment by a temporary hardenable material construction apparatus comprising: a support structure comprising a support frame, a first inner support arm extending from the support frame and a first outer support arm extending from the support frame; at least one support extension member, the at least one support extension member exhibiting a first end and a second end opposing the first end; a first enclosure member exhibiting an inner face and an outer face opposing the inner face; and a second enclosure member exhibiting an inner face and an outer face opposing the inner face, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined between the inner face of the first enclosure member and the inner face of the second enclosure member, wherein the first outer support arm is juxtaposed with the outer face of the first enclosure member, wherein the first inner support arm is juxtaposed with the outer face of the second enclosure member, wherein the at least one support extension member extends through the first enclosure member and the second enclosure member such that the first end of the at least one support extension member extends past the outer face of the first enclosure member and the second end of the at least one support extension member extends past the outer face of the second enclosure member, and wherein the first end of the at least one support extension member is secured to the first outer support arm and the second end of the at least one support extension member is secured to the first inner support arm.
- In one embodiment, the support structure further comprises a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the first outer support arm being secured to the first extension arm and the extension of the first inner support arm from the support frame responsive to the first inner support arm being secured to the first extension arm. In one further embodiment, the support structure further comprises a second extension arm extending from the support frame, a second inner support arm secured to the second extension arm and a second outer support arm secured to the second extension arm, wherein the at least one support extension member comprises a plurality of support extension members, the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of the plurality of support extension members secured to the second inner support arm.
- In one embodiment, the support structure further comprises a plurality of elongated strengthening arms, each exhibiting a first end and a second end opposing the first end, wherein the first end of each of the plurality of elongated strengthening arms is secured to the first inner support arm and the second end of each of the plurality of elongated strengthening arms is secured to the second inner support arm. In another embodiment, the distance between the support frame and the second enclosure member is 60-120 centimeters.
- In one embodiment, the distance between the support frame and the second enclosure member is 80-100 centimeters. In another embodiment, the apparatus further comprises a plurality of free extension members, each of the plurality of free extension members exhibiting a first end and a second end opposing the first end, wherein each of the plurality of free extension members extends through the first enclosure member and the second enclosure member, and wherein the first end of each of the plurality of free extension members is not secured to the first outer support arm and the second end of each of the plurality of free extension members is not secured to the first inner support arm.
- In one embodiment, the first inner support arm extends across the entirety of the outer face of the second enclosure member, wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member. In another embodiment, the first enclosure member comprises: a plurality of strips; and a plurality of slabs, each of the plurality of slabs exhibiting a first face, a second face opposing the first face, a first side extending from the first face to the second face and a second side opposing the first side, each of the first side and the second side exhibiting a slit therealong, the slit configured to receive a respective one of the plurality of strips, wherein the first side of each of the plurality of slabs faces the second side of another of the plurality of slabs, a respective one of the plurality of strips disposed within the slit of the first side of the respective slab and within the slit of the second side of the another respective slab, and wherein each of the at least one support extension member extends through a respective one of the plurality of strips. In one further embodiment, the apparatus further comprises a plurality of L-shaped corner members, each of the L-shaped corner members exhibiting a first end and a second end perpendicular to the first end, the slit of each of the plurality of slabs further configured to receive one of a first end and a second end of a respective one of the plurality of L-shaped corner members, wherein the at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, the first end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a first of the pair of first enclosure members and the second end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a second of the pair of first enclosure members.
- In one embodiment, the first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members, wherein each of the at least one support extension member extends through a respective one of the plurality of facade securing elements. In another embodiment, the first enclosure member comprises: an outer layer exhibiting an inner face and an outer face opposing the inner face, the outer face of the first enclosure member comprising the outer face of the outer layer; and an insulation layer exhibiting an inner face and an outer face opposing the inner face, the inner face of the insulation layer facing the inner face of the second enclosure member, the outer face of the insulation layer facing the inner face of the outer layer.
- In one further embodiment, the outer face of the insulation layer is in direct contact with the inner face of the outer layer. In one yet further embodiment, the apparatus further comprises: a grid assembly disposed within the defined space; at least one securing member, each of the at least one securing members disposed on a respective one of the at least one support extension member and juxtaposed with the insulation layer to secure the insulation layer to the outer layer; and wherein the grid assembly is secured to the at least one extension member so as to separate the grid assembly from the insulation layer by at least a predetermined distance.
- In one independent embodiment, a structure is provided, the structure comprising: a plurality of extension members, each of the plurality of extension members exhibiting a first end and a second end opposing the first end; a first enclosure member exhibiting an inner face and an outer face opposing the inner face; and a second enclosure member exhibiting an inner face and an outer face opposing the inner face, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined between the inner face of the first enclosure member and the inner face of the second enclosure member, the space filled with a wall layer of hardenable material; wherein each of the plurality of extension members extends through the first enclosure member and the second enclosure member, and wherein the first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members, wherein each of the plurality of extension members extends through a respective one of the plurality of facade securing elements.
- In one embodiment, each of the plurality of facade securing elements comprises a strip, wherein each of the plurality of facade members comprises a slab, each of the plurality of slabs exhibiting a first face, a second face opposing the first face, a first side extending from the first face to the second face and a second side opposing the first side, each of the first side and the second side exhibiting a slit therealong, the slit configured to receive a respective one of the plurality of strips, and wherein the first side of each of the plurality of slabs faces the second side of another of the plurality of slabs, a respective one of the plurality of strips disposed within the slit of the first side of the respective slab and within the slit of the second side of the another respective slab, each of the plurality of extension members extending through a respective one of the plurality of strips. In one further embodiment, the structure further comprises a plurality of L-shaped corner members, each of the L-shaped corner members exhibiting a first end and a second end perpendicular to the first end, the slit of each of the plurality of slabs further configured to receive one of a first end and a second end of a respective one of the plurality of L-shaped corner members, wherein the at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, the first end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a first of the pair of first enclosure members and the second end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a second of the pair of first enclosure members.
- In another embodiment, the first enclosure member comprises: an outer layer exhibiting an inner face and an outer face opposing the inner face, the outer face of the first enclosure member comprising the outer face of the outer layer, the outer layer comprising the plurality of facade members and the plurality of facade securing elements; and an insulation layer exhibiting an inner face and an outer face opposing the inner face, the inner face of the insulation layer facing the inner face of the second enclosure member, the outer face of the insulation layer facing the inner face of the outer layer. In one further embodiment, the outer face of the insulation layer is in direct contact with the inner face of the outer layer.
- In another further embodiment, the structure further comprises: a grid assembly disposed within the hardenable material; a plurality of securing members, each of the plurality of securing members disposed on a respective one of the plurality of extension members and juxtaposed with the insulation layer to secure the insulation layer to the outer layer; and wherein the grid assembly is secured to one of the plurality of extension members so as to separate the grid assembly from the insulation layer by at least a predetermined distance.
- In one embodiment, the structure further comprises: a ceiling panel positioned over the second enclosure member; and a ceiling layer of hardenable material disposed on the ceiling panel, the insulation layer of the first enclosure member rising above the ceiling layer of hardenable material.
- In another independent embodiment, a hardenable material construction method is provided, the method comprising: juxtaposing an outer face of a first enclosure member to a first outer support arm, the first outer support arm extending from a support frame; securing a first end of at least one support extension member to the first outer support arm; juxtaposing a first inner support arm to an outer face of a second enclosure member, the first inner support arm extending from a support frame; securing a second end of the at least one support extension member to the first inner support arm; and subsequent to the securing the at least one support extension member to the first inner support arm, placing hardenable material into the space defined between an inner face of the first enclosure member and an inner face of the second enclosure member, the inner face of the first enclosure member opposing the outer face of the first enclosure member and the inner face of the second enclosure member opposing the outer face of the second enclosure member, wherein the secured at least one support extension member extends through the first enclosure member and the second enclosure member.
- In one embodiment, the method further comprises, prior to the placing: securing the first outer support arm to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the securing; and securing the first inner support arm to the first extension arm, the extension of the first inner support arm from the support frame responsive to the securing. In one further embodiment, the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to the placing: securing a second outer support arm to a second extension arm extending from the support frame; and securing a second inner support arm to the second extension arm, wherein the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of the plurality of support extension members secured to the second inner support arm.
- In one embodiment, the method further comprises, prior to the placing: securing a first end of each of a plurality of elongated strengthening arms to the first inner support arm; and securing a second end of each of the plurality of elongated strengthening arms to the support frame. In another embodiment, the distance between the support frame and the second enclosure member is 60-120 centimeters.
- In one embodiment, the distance between the support frame and the second enclosure member is 80-100 centimeters. In another embodiment, the method further comprises, prior to the placing, extending a plurality of free extension members through the first enclosure member and the second enclosure member, wherein the extended free extension members are not secured to the first inner support arm or to the first outer support arm.
- In one embodiment, the first inner support arm extends across the entirety of the outer face of the second enclosure member, and wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member. In another embodiment, the method further comprises: a) positioning a first side of each of a plurality of slabs to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof, the first side and second side of each of the plurality of slabs exhibiting a slit configured to receive a respective one of a plurality of strips; b) disposing a respective one of the plurality of strips within the slit of the first side of each of the plurality of slabs and the slit of the second side of the respective another slab; and c) inserting each of the at least on support extension member through a respective one of the plurality of strips, wherein the first enclosure member is formed responsive to steps a-b.
- In one further embodiment, the method further comprises disposing each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, within the slit of the first side of a first of the plurality of slabs and within the slit of the first side of a second of the plurality of slabs.
- In one embodiment, the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to the placing, inserting each of the plurality of support extension members through a respective one of a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of a plurality of facade members, wherein the first enclosure member comprises the plurality of facade members. In another embodiment, the method further comprises, prior to the placing: d) positioning an outer face of an insulation layer to face an inner face of an outer layer so as to form the first enclosure member, wherein the outer layer exhibits an outer face opposing the inner face thereof, the outer face of the first enclosure member comprising the outer face of the outer layer, and wherein the insulation layer exhibits an inner face opposing the outer face thereof, the inner face of the first enclosure member comprising the inner face of the insulation layer.
- In one further embodiment, step d comprises positioning the outer face of the insulation layer to be in direct contact with the inner face of the outer layer. In another further embodiment, the method further comprises, prior to the placing: disposing a grid assembly within the space defined between the first enclosure member and the second enclosure member; securing the insulation layer to the outer layer with a plurality of securing members, each of the plurality of securing members disposed on a respective one of the plurality of extension members; and securing the grid assembly to one of the plurality of extension members so as to separate the grid assembly from the insulation layer by at least a predetermined distance.
- Additional features and advantages of the invention will become apparent from the following drawings and description.
- For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings in which like numerals designate corresponding elements or sections throughout.
- With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
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FIGS. 1A-1B illustrate various high level views of a temporary hardenable material construction apparatus comprising freestandable support frames, according to certain embodiments; -
FIG. 1C illustrates a high level perspective view of the temporary hardenable material construction apparatus ofFIGS. 1A-1B further comprising hardenable material, according to certain embodiments; -
FIG. 1D illustrates a high level perspective view of a wall of the hardenable material ofFIG. 1C , without the freestandable support frames ofFIGS. 1A-1B , according to certain embodiments; -
FIGS. 2A-2B illustrate various high level views of an enclosure member comprising a plurality of slitted slabs and a plurality of strips disposed therewithin, according to certain embodiments; -
FIG. 2C illustrates a high level view of a slab ofFIGS. 2A-2B , according to certain embodiments; -
FIG. 2D illustrates a high level view of a strip ofFIGS. 2A-2B , according to certain embodiments; -
FIG. 2E illustrates a high level view of a temporary hardenable material construction apparatus comprising the enclosure member ofFIGS. 2A-2B , according to certain embodiments; -
FIG. 2F illustrates a high level view of the temporary hardenable material construction apparatus ofFIG. 2E , further comprising an insulation layer, according to certain embodiments; -
FIG. 2G illustrates a high level view of a portion of the temporary hardenable material construction apparatus ofFIG. 2E , according to certain embodiments; -
FIG. 2H illustrates a high level view of an L-shaped corner member, according to certain embodiments; -
FIG. 2I illustrates a high level view of a pair of perpendicularly positioned enclosure members ofFIGS. 2A-2B , according to certain embodiments; -
FIGS. 3A-3D illustrate various high level views of a temporary hardenable material construction apparatus further comprising a pair of grid assemblies and a double layer enclosure member, according to certain embodiments; -
FIG. 4 illustrates a high level schematic top view of a temporary hardenable material construction apparatus comprising a spiral staircase, according to certain embodiments; -
FIGS. 5A-5E illustrate various high level views of a temporary hardenable material construction apparatus comprising a ceiling panel, according to certain embodiments; -
FIG. 5F illustrates a high level perspective view of a temporary hardenable material construction apparatus in an advanced stage of construction, according to certain embodiments; -
FIG. 5G illustrates a high level perspective view of a freestandable support frame configured with separate upper and lower sections, according to certain embodiments; -
FIGS. 6A-6C illustrate various high level flow charts of a first hardenable material construction method, according to certain embodiments; -
FIGS. 7A-7I illustrates various high level views of various stages of construction using a temporary hardenable material construction apparatus comprising support structures, according to certain embodiments; and -
FIGS. 8A-8B illustrate various high level flow charts of a second hardenable material construction method, according to certain embodiments. - Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
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FIG. 1A illustrates a high level perspective view of a temporary hardenablematerial construction apparatus 10 andFIG. 1B illustrates a high level side view of temporary hardenablematerial construction apparatus 10,FIGS. 1A-1B being described together. - Temporary hardenable
material construction apparatus 10 comprises: a plurality of freestandable support frames 20, each exhibiting afirst face 22, asecond face 24 opposingfirst face 22, a plurality of receiving members 25 (not shown) extending acrossfirst face 22, abase portion 26, atop portion 27 opposingbase portion 26, afirst side 28 and asecond side 29 opposingfirst side 28; a plurality of freestandable support frames 30, each exhibiting afirst face 32, a second face 34 opposingfirst face 32, a plurality of receivingmembers 35 extending acrossfirst face 32, abase portion 36, atop portion 37 opposingbase portion 36, afirst side 38 and asecond side 39 opposingfirst side 38; a plurality ofextension members 40, each exhibiting afirst end 42 and asecond end 44 opposingfirst end 42; anenclosure member 50, exhibiting aninner face 52 and anouter face 54 opposinginner face 52; and anenclosure member 60, exhibiting aninner face 62 and anouter face 64 opposinginner face 62. - The term ‘freestandable’, as used herein, means that the support frame is able to stand on its own when placed on a surface without any additional supports securing it to another support structure or the ground. In one embodiment, each
freestandable support frame members 25, 35 of each respectivefreestandable support frame first face members 25, 35 extend vertically across the respectivefirst face members 25, 35 of each respectivefreestandable support frame first face - First
freestandable support members 20 and secondfreestandable support members 30 are each illustrated as being generally rectangular shaped, however this is not meant to be limiting in any way. Particularly, firstfreestandable support members 20 and secondfreestandable support members 30 are shaped in accordance to the shapes ofenclosure member 50 andenclosure member 60, which can be provided in any shape according to the construction plans. -
First side 28 andsecond side 29 of eachfreestandable support frame 20 extends fromfirst face 22 tosecond face 24 and frombase portion 26 totop portion 27. In one embodiment,first sides 28 andsecond sides 29 are each open, i.e. a person can walk therethrough. In another embodiment,base portion 26 of eachfreestandable support frame 20 is a generally flat and closed surface. In one embodiment, the distance betweenfirst face 22 andsecond face 24 of eachfreestandable support frame 20 is about 120 centimeters. Particularly, the distance betweenfirst face 22 andsecond face 24 is arranged such that two people can both work side by side within a singlefreestandable support frame 20. In another embodiment, the distance betweenfirst side 28 andsecond side 29 of eachfreestandable support frame 20 is about 60 centimeters.First side 38 andsecond side 39 of eachfreestandable support frame 30 extends fromfirst face 32 to second face 34 and frombase portion 36 totop portion 37. In one embodiment, the distance betweenfirst face 32 and second face 34 of eachfreestandable support frame 30 is at least 60 centimeters, optionally about 60 centimeters. In another embodiment, the distance betweenfirst side 38 andsecond side 39 of eachfreestandable support frame 30 is at least 120 centimeter, optionally about 120 centimeters. These dimensions allow for freestandable support frames 20, 30 to have a wide enough base to support themselves to be freestandable while also allowing a comfortable work space therein. In one non-limiting embodiment, the distance betweenbase portion 26 andtop portion 27, and the distance betweenbase portion 36 andtop portion 37, is at least 2 meters, optionally at least 2.7 meters, so as to allow the construction of a building wall. In one embodiment, each of first faces 22 and 32, second faces 24 and 34,base portions top portions second sides - As will be described below, in one embodiment each
extension member 40 exhibits a plurality of grooves.Enclosure member 50 is positioned in parallel withenclosure member 60 such that aspace 70 is defined betweeninner face 52 ofenclosure member 50 andinner face 62 ofenclosure member 60. Thus,inner face 52 is defined as the face ofenclosure member 50 which faces, and defines,space 70 andouter face 54 is defined as the face ofenclosure member 50 which faces away fromspace 70. Similarly,inner face 62 is defined as the face ofenclosure member 60 which faces, and defines,space 70 andouter face 64 is defined as the face ofenclosure member 60 which faces away fromspace 70. As will be described below, a hardenable material is arranged to be poured intospace 70. - First face 22 of each
freestandable support frame 20 is juxtaposed withouter face 54 ofenclosure member 50 and in one embodiment is flush therewith. As illustrated,first face 22 of eachfreestandable support frame 20 is substantially completely covered byouter face 54 ofenclosure member 50. In one embodiment, as illustrated,first face 22 is rectangular shaped, with the sides offirst face 22 which are defined byfirst side 28 andsecond side 29 being longer than the sides offirst face 22 which are defined bybase portion 26 andtop portion 27.First side 28 of eachfreestandable support frame 20 facessecond side 29 of an adjacently positionedfreestandable support frame 20 so as to form a row of freestandable support frames 20. In one embodiment, eachfreestandable support frame 20 is secured to an adjacentfreestandable support frame 20. First face 32 of eachfreestandable support frame 30 is juxtaposed withouter face 64 ofenclosure member 60 and in one embodiment is flush therewith. As illustrated,first face 32 of eachfreestandable support frame 30 is substantially completely covered byouter face 64 ofenclosure member 60. In one embodiment, as illustrated,first face 32 is rectangular shaped, with the sides offirst face 32 which are defined byfirst side 38 andsecond side 39 being longer than the sides offirst face 32 which are defined bybase portion 36 andtop portion 37.First side 38 of eachfreestandable support frame 30 facessecond side 39 of an adjacently positionedfreestandable support frame 30 so as to form a row of freestandable support frames 30. In one embodiment, eachfreestandable support frame 30 is secured to an adjacentfreestandable support frame 30. - Each
extension member 40 extends throughenclosure member 50,space 70 andenclosure member 60 such thatfirst end 42 of eachextension member 40 extends pastouter face 54 ofenclosure member 50 andsecond end 44 of eachextension member 40 extends pastouter face 64 ofenclosure member 60. Additionally,first end 42 of eachextension member 40 is secured to a receiving member 25 of a respective one of freestandable support frames 20. In one embodiment, where freestandable support frames 20 are constituted of wood or plastic,first end 42 extends through the respective receiving member 25 and is secured thereto on one or both sides thereof. In another embodiment, where freestandable support frames 20 are constituted of metal,first end 42 is welded to the respective receiving member 25. Additionally,second end 44 of eachextension member 40 is secured to a receivingmember 35 of a respective one of freestandable support frames 30. In one embodiment, where freestandable support frames 30 are constituted of wood or plastic,second end 44 extends through the respective receivingmember 35 and is secured thereto on one or both sides thereof. In another embodiment, where freestandable support frames 30 are constituted of metal,second end 44 is welded to the respective receivingmember 35. In one embodiment, 24extension members 40 are secured to eachfreestandable support frame 20. - In one embodiment, as will be described further below in relation to temporary hardenable
material construction apparatus 300, a steel grid assembly may be disposed withinspace 70. In another embodiment, water and sanitation pipes and electric wiring may be disposed withinspace 70 prior to pouring the hardenable material described below. - Temporary hardenable
material construction apparatus 10 is illustrated and described as comprising a plurality of freestandable support frames 20 and a plurality of freestandable support frames 30, however this is not meant to be limiting in any way and a singlefreestandable support frame 20 and a singlefreestandable support frame 30 may be provided without exceeding the scope. Advantageously, utilizing a plurality of freestandable support frames 20, 30 allows for the use of smaller support frames which are light, easily portable and do not require a complex manufacturing process. - As illustrated in
FIG. 1C , ahardenable material 80 is poured intospace 70. In one embodiment,hardenable material 80 comprises concrete. In another embodiment,hardenable material 80 comprises any fluidic material which hardens. For clarity,FIGS. 1A-1C are illustrated wherespace 70 is open at the ends ofenclosure members material construction apparatus 10 is particularly contemplated as comprising means for containinghardenable material 80 withinspace 70. In one embodiment, as will be described below in relation to temporary hardenablematerial construction apparatus 500, fourperpendicular spaces 70 are constructed thereby creating a single enclosed space forhardenable material 80. In another embodiment, the ends ofspace 70 are covered with material to holdhardenable material 80 therein. - As illustrated in
FIG. 1D , afterhardenable material 80 is poured intospace 70, and is allowed to harden, freestandable support frames 20, 30 are removed.First end 42 andsecond end 44 of eachextendable member 40 is then sawed off. Awall 90 is thus provided, comprisingenclosure members hardenable material 80. Advantageously, the hardenedhardenable material 80 doesn't have to be covered with additional wall sections, sinceenclosure members enclosure members hardenable material 80 hardens, so the hardenedhardenable material 80 can be covered with other materials or left exposed. As will be described further below, in oneembodiment enclosure member 50 is secured to the hardenedhardenable material 80 by extendingmembers 40 andenclosure member 60 is secured to the hardened hardenable material by protrusions extending therefrom. Further advantageously, freestandable support frames 20, 30 can be reused since they do not need to be disassembled to be removed fromwall 90. - Temporary hardenable
material construction apparatus 10 has been describe and illustrated as comprising one or more freestandable support frames 20 and one or more freestandable support frames 30, however this is not meant to be limiting in any way. In another embodiment, freestandable support frames 30 are not provided andextension members 40 are secured to freestandable support frames 20. In another embodiment, freestandable support frames 20 are not provided andextension members 40 are secured to freestandable support frames 30. - In one embodiment (not shown),
enclosure member 50 comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members. First end 42 of eachextension member 40 extends through a respective one of the plurality of facade securing elements. The facade members are members which form a facade, such as stones. The facade members can exhibit any shape and dimensions which are desired. Optionally, the perimeter of each facade member, i.e. the sides thereof, exhibit a plurality of insertion holes, each the insertion holes containing a respective one of the plurality of facade securing elements. The facade securing elements are each designed to exhibit an opening to receive therethrough anextension member 40.Enclosure member 50 is formed by positioning the facade members along a single plane, each facade member optionally secured to an adjacent facade member with appropriate material, such as mortar. -
FIG. 2A illustrates a high level perspective view of a portion of anenclosure member 100 comprising a plurality ofslabs 110 and a plurality ofstrips 120.FIG. 2B illustrates a full high level perspective view ofenclosure member 100.FIG. 2C illustrates a high level perspective view of aslab 110.FIG. 2D illustrates a high level perspective view of astrip 120.FIG. 2E illustrates a high level perspective view of a temporary hardenablematerial construction apparatus 200.FIG. 2F illustrates a high level perspective view of temporary hardenablematerial construction apparatus 200 further comprising an insulation layer.FIG. 2G illustrates a high level perspective view of temporary hardenablematerial construction apparatus 200 without freestandable support frames for clarity.FIG. 2H illustrates a high level perspective view of an L-shapedcorner member 210.FIG. 2I illustrates a high level perspective view of a pair of perpendicularly positionedenclosure members 100 secured to each other with a plurality of L-shapedcorner members 210.FIGS. 2A-21 will be described together. - Each
slab 110 exhibits: afirst face 111; asecond face 112 opposingfirst face 111; afirst side 113 extending fromfirst face 111 tosecond face 112; asecond side 114 extending fromfirst face 111 tosecond face 112 and opposingfirst side 113; athird side 115 extending fromfirst face 111 tosecond face 112 and fromfirst side 113 tosecond side 114; and afourth side 116 extending fromfirst face 111 tosecond face 112 and fromfirst side 113 tosecond side 114,fourth side 116 opposingthird side 115.First side 113 andsecond side 114 of eachslab 110 exhibits aslit 130 extending therealong fromthird side 115 tofourth side 116.Slits 130 are each configured to receive arespective strip 120. Particularly, the width ofslit 130 is configured to be greater than, or equal to, the thickness of eachstrip 120. - As illustrated in
FIGS. 2A-2B ,enclosure member 100 is formed of a plurality of columns ofslabs 110. Particularly, each column ofslabs 110 comprises a plurality ofslabs 110 on top of each other such thatfirst side 113 of eachslab 110 facessecond side 114 of anadjacent slab 110. Columns ofslabs 110 are positioned next to each other to form rows ofslabs 110 such thatthird side 115 of eachslab 110 facesfourth side 116 of anadjacent slab 110. Eachstrip 120 is disposed withinslit 130 offirst side 113 of arespective slab 110 and withinslit 130 ofsecond side 114 of theadjacent slab 110 which faces the respectivefirst side 113. In one embodiment, the length of eachstrip 120 is greater than the length of each slit 130 such that eachstrip 120 is disposed withinslits 130 ofslabs 110 from more than one column. In another embodiment, the length of eachstrip 120 is not greater than the length of eachslit 130, however strips 120 are disposed withinslits 130 such that eachstrip 120 is disposed withinslits 130 ofslabs 110 from more than one column. As illustrated inFIG. 2D , eachstrip 120 exhibits one or more holes. - Temporary hardenable
material construction apparatus 200 ofFIG. 2E is in all respects similar to temporary hardenablematerial construction apparatus 10, with the exception thatenclosure member 50 is replaced withenclosure member 100. As illustrated inFIG. 2G , where freestandablemembers extension members 40 extend throughholes 140 ofstrips 120. In one embodiment, after insertion throughholes 140,extension members 40 are each welded to therespective strip 120. In another embodiment,extension members 40 each comprise a plurality of grooves and a nut is threaded onto eachextension member 40 on one or both sides of therespective strip 120. Securingenclosure member 100 with nuts, or by welding, keepsenclosure member 100 from sliding alongextension members 40. - In one embodiment, the depth of each slit 130 is configured to be less than half the width of each
strip 120 such that whenstrip 120 is disposed withinslits 130 of the respectiveadjacent slabs 110,slabs 110 do not meet and there is aspace 135 betweenfirst side 113 of a first of theadjacent slabs 110 andsecond side 114 of the second of theadjacent slabs 110, therespective extension member 40 extending through thespace 135 between the respectivefirst side 113 andsecond side 114. - In another embodiment, when forming
enclosure member 100, afirst slab 110 is positioned and astrip 120 is disposed withinslit 130 offirst side 113 thereof. At least twoextension members 40 are then inserted throughrespective holes 140 of the disposedstrip 120. Anadditional slab 110 is then position on top of thefirst slab 110 such that thedisposed strip 120 is additionally disposed withinsecond side 114 of theadditional slab 110, the separation of theadjacent slabs 110 being maintained by the insertedextension members 40. - In order to add a window or door within the wall, a predetermined number of
slabs 110 are left out ofenclosure member 100. In place of the left outslabs 110, a frame is inserted which extends throughspace 70 thereby not allowing hardenable material to enter the space surrounded by the inserted frame. - After hardenable material is poured into
space 70, freestandable support frames 20, 30 are removed and first and second ends 42, 44 of eachextension member 40 is sawed off. In one embodiment, the space between each adjacent pair ofslabs 110 is filled with a filling material. - In one embodiment, as illustrated in
FIG. 2F , aninsulation layer 150 is further provided, juxtaposed withsecond faces 112 ofslabs 110, as will be described below in relation to temporary hardenablematerial construction apparatus 300. - As illustrated in
FIG. 2I , a pair ofenclosure members 100 are illustrated being positioned perpendicularly to each other. A plurality of L-shapedcorner members 210, illustrated inFIG. 2H , are arranged to connect the pair ofenclosure members 100. Particularly, each L-shapedcorner member 210 exhibits afirst half 212 and asecond half 214,second half 214 being perpendicular tofirst half 212.First half 212 of each L-shapedcorner member 210 is disposed withinrespective slits 130 of a first of the pair of perpendicularly positionedenclosure members 100 andsecond half 214 of each L-shapedcorner member 210 is disposed withinrespective slits 130 of the second of the pair of perpendicularly positionedenclosure members 100. Preferably, L-shapedcorner members 210 are each formed as a single piece, i.e. not two separate pieces which are welded or screwed together. Therefore, when hardenable material is poured intospace 70 defined by bothenclosure members 100, L-shapedcorner members 210secure enclosure members 100 to each other so as not separate responsive to the pressure applied by the poured hardenable material. - In another embodiment (not shown),
slabs 110 are provided with slits withinfirst face 111, the slits being of appropriate shape and size such that astrip 120, or a portion thereof, can be inserted therein and secured toslab 110.Extension members 40 are secured tostrips 120, optionally by welding. Since the slits are withinfirst face 111, thereby facingspace 70, and not betweenadjacent slabs 110,extension members 40 do not interfere with the placement ofslabs 110 and the rows ofslabs 110 can be flush with each other. -
FIG. 3A illustrates a perspective view of a temporary hardenablematerial construction apparatus 300; andFIG. 3B illustrates a side view of temporary hardenablematerial construction apparatus 300,FIGS. 3A-3B being described together. Temporary hardenablematerial construction apparatus 300 is in all respects similar to temporary hardenablematerial construction apparatus 10, further comprising a pair ofgrid assemblies 310 and a plurality of securingmembers 320. Additionally,enclosure member 50 is replaced with anenclosure member 330. -
Enclosure member 330 comprises: anouter layer 340 exhibiting aninner face 342 and an outer face 344 opposinginner face 342; and aninsulation layer 350 exhibiting aninner face 352 and anouter face 354. In one embodiment,outer face 354 ofinsulation layer 350 is in direct contact withinner face 342 ofouter layer 340, i.e. there is no plaster betweeninsulation layer 350 andouter layer 340. As a result, when condensation trapped betweeninsulation layer 350 andouter layer 340 turns into droplets during the night, the droplets will slide downinner face 342 ofouter layer 340 andouter face 354 ofinsulation layer 350 until reaching the ground. Advantageously, the condensation does not remain betweeninsulation layer 350 andouter layer 340 and thus will not expand during the day and cause damage and deformations ofouter layer 340. - In one embodiment, as described above in relation to temporary hardenable
material construction apparatus 200,outer layer 340 comprises a plurality of slitted slabs coupled together with strips disposed within the slits of the slabs. In one embodiment,insulation layer 350 comprises a panel of insulating material, such as polystyrene. In another embodiment,insulation layer 350 comprises a hardenable insulating material which is sprayed ontoinner face 342 ofouter layer 340, thereby forming a hardened insulation layer overinner face 342.Inner face 342 ofouter layer 340 facesouter face 354 ofinsulation layer 350.Inner face 352 ofinsulation layer 350 facesinner face 62 ofenclosure member 60,space 70 being defined byinner face 62 ofenclosure member 60 andinner face 352 ofinsulation layer 350. - Each
grid assembly 310 is constructed of a grid of horizontal and vertical bars, preferably steel bars. Eachgrid assembly 310 is separated from a respective one ofenclosure member 330 andenclosure member 60 by at least a predetermined distance. Preferably, the predetermined distance is 1.5 centimeters. A pair of separation members may be attached to eachextension member 40, optionally screwed thereon. The separation members are arranged to keepgrid assemblies 310 from becoming too close to therespective enclosure member grid assembly 310 will be completely covered by the poured hardenable material and to thereby retard corrosion of the grid bars. In the event thatgrid assemblies 310 become too close to therespective enclosure members - Each securing
member 320 is attached to a respective one ofextension members 40, preferably screwed thereon, and disposed oninner face 352 ofinsulation layer 350. Securingmembers 320 are arranged to pressinsulation layer 350 againstouter layer 340 to secureinsulation layer 350 toouter layer 340 to further maintain the predetermined distance betweeninsulation layer 350 and theadjacent grid assembly 310. In one embodiment (not shown), an additional securing member is attached to eachextension member 40 and disposed oninner face 62 ofenclosure member 60 to secureenclosure member 60 to freestandable support frames 30 while maintaining smooth contact therewith. Particularly, in the event that a nut is screwed onto anextension member 40 and pressed againstouter wall 64 ofenclosure member 60, the additional securing member is arranged to secureenclosure member 60 so as not to accidentally be pushed or distorted from pressing the nut too much intoouter wall 64. - In one embodiment,
grid assemblies 310 are welded to at least some ofextension members 40 at the predetermined distance from the respective one ofenclosure members - In addition, each
grid assembly 310, which may be positioned to be substantially parallel toenclosure members extension members 40, may be welded to a plurality ofextension members 40. - More particularly, bars of each grid assembly 310 may be welded to the extension members 40 by a weld formation to define a plurality of rectilinear hoops H. Each hoop H is typically defined by eight welds: (1) weld j at the junction of a first extension member 40 and a first vertical bar of grid assembly 310, (2) weld k at the junction of the first extension member and a second vertical bar of grid assembly 310 which is transversally spaced from the first extension member, (3) weld 1 at the junction of a second extension member located directly below the first extension member and the first vertical bar, (4) weld m at the junction of the second extension member and the second vertical bar, (5) weld j′ (not shown) at the junction of a third extension member being at the same height as, and longitudinally spaced from, the first extension member and a third vertical bar longitudinally spaced from the first vertical bar, (6) weld k′ (not shown) at the junction of the third extension member and a fourth vertical bar transversally spaced from the third extension member, (7) weld l′ (not shown) at the junction of a fourth extension member located directly below the third extension member and the third vertical bar, and (8) weld m′ (not shown) at the junction of the fourth extension member and the fourth vertical bar.
- Similarly, a hoop may be defined by a weld at the junction of an extension member and a horizontal bar of
grid assembly 310. Following the formation of a plurality of hoops H and the pouring and setting of the hardenable material, a reinforced wall structure of superior impact resistance is produced. Each hoop H confines a corresponding volume of the hardened material, particularly concrete, and significantly increases the strain capacity, often as much as ten-fold. The hoops H act to restrain dilation of the hardened material as it is loaded in compression, and this confining action leads to increased compressive strength and strain capacity. Indeed, tests conducted by the Applicant indicated that the impact resistance of the hoop-reinforced wall structure of the present invention has an impact resistance of greater than 40% relative to prior art wall structures that are reinforced only by a grid assembly, and not by hoops. - It will be appreciated that improved impact resistance will be realized even when a hoop H is not contiguous with an adjacent hoop, although optimum impact resistance is achieved when a wall structure includes continuous and contiguous hoops.
- The hoops generally follow the shape of the wall structure, whether rectilinear or curvilinear, although the hoops may assume a different shape than the wall structure, depending on the type of grid assembly used and the relative placement of the grid assembly. Following placement of the grid assembly, a reinforcement splice or crosstie may be employed to connect between an extension member and the grid assembly if there is a gap therebetween.
- In another embodiment, as shown in
FIG. 3C , aprebent grid assembly 370 may be employed. A planar grid assembly is preferably bent at a factory by a dedicated bending machine to produceprebent grid assembly 370, but may be also be bent in situ.Prebent grid assembly 370 has a rectilinear configuration with twolongitudinal portions longitudinal portion 372 which is the longest longitudinal portion and the firsttransversal portion 376 which is the longest transversal portion are adjacent and substantially perpendicular to each other. - The second
transversal portion 377 which is adjacent and substantially perpendicular to the secondlongitudinal portion 373 and the thirdtransversal portion 378 which is adjacent and substantially perpendicular to the firstlongitudinal portion 372 may overlap each other. For example, firstlongitudinal portion 372 has a length of 120 cm and firsttransversal portion 376 has a length of 15 cm. - As shown in
FIG. 3D , the use ofprebent grid assembly 370 advantageously allows the reinforced wall structure to have an increased number of hoops for a given wall thickness. Extension members are welded to portions ofprebent grid assembly 370 to define each hoop. -
Prebent grid assembly 370 is positioned in the space between the inner and outer standable support frames, and of course additional longitudinally spaced prebent grid assemblies may also be positioned in the space between the inner and outer standable support frames. - A three-dimensional hoop K is typically defined by eight welds: (1) weld s at the junction of first extension member 40A and first longitudinal portion 372 of a first bent bar of the grid assembly, (2) weld t at the junction of first extension member 40A and second longitudinal portion 373 of the first bent bar, (3) weld s′ (not shown) at the junction of a second extension member located directly below first extension member 40A and first longitudinal portion 372 of a second bent bar located below the first bent bar, (4) weld t′ at the junction of the second extension member and second longitudinal portion 373 of the second vertical bar, (5) weld u at the junction of third extension member 40C being at the same height as, and longitudinally spaced from, first extension member 40A and first longitudinal portion 372 of a first bent bar, (6) weld v at the junction of third extension member 40C and second longitudinal portion 373 of the first bent bar, (7) weld u′ (not shown) at the junction of a fourth extension member located directly below third extension member 40C and first longitudinal portion 372 of the second bent bar, and (8) weld v′ (not shown) at the junction of the fourth extension member and second longitudinal portion 373 of the second bent bar. A vertical bar of
prebent grid assembly 370 generally extends between each pair of welds s-s′, t-t′, u-u′ and v-v′ to complete the three-dimensional hoop K. - An additional hoop L of smaller dimensions may be formed from
first extension member 40A between welds s and t, firsttransversal portion 376, firstlongitudinal portion 372 between firsttransversal portion 376 and weld s, and secondlongitudinal portion 373 between firsttransversal portion 376 and weld t. Tests conducted by the Applicant indicated that the impact resistance of a hoop reinforced wall structure that is additionally reinforced by a prebent grid assembly has an impact resistance of greater than 60% relative to prior art wall structures that are reinforced only by a grid assembly, and not by hoops. A wall structure having such a high impact resistance is able to remain intact after being impacted by a projectile having a speed of up to 2500 kilometer/hr. -
FIG. 4 illustrates a high level schematic diagram of a high level top view of a portion of a temporary hardenablematerial construction apparatus 400. Temporary hardenablematerial construction apparatus 400 comprises a pair of temporary hardenablematerial construction apparatuses 300 positioned perpendicularly to each other. Temporary hardenablematerial construction apparatus 400 further comprises aspiral staircase 410 at acorner 420 where perpendicularly positioned temporary hardenablematerial construction apparatuses 300 meet. As illustrated, a space exists between the ultimatefreestandable support frame 20 of a first of the pair of temporary hardenablematerial construction apparatuses 300 and the ultimatefreestandable support frame 20 of the second of the pair of temporary hardenablematerial construction apparatuses 300 atcorner 420,spiral staircase 410 positioned within the empty space ofcorner 420.Spiral staircase 410 is arranged to rise to the height oftop portions 27 of freestandable support frames 20 so that a second level of freestandable support frames 20, which are disposed on top of the first level of freestandable support frames 20, is easily accessible. If additional levels of freestandable support frames 20 are provided, as will be described further below,spiral staircase 410 is arranged to rise to the highest level of freestandable support frames 20. For simplicity, only a portion of each temporary hardenablematerial construction apparatus 300 is illustrated. Additionally, for simplicity,grid assemblies 310 and securingmembers 320 are not illustrated. -
FIG. 5A illustrates a high level perspective view of a portion of a temporary hardenablematerial construction apparatus 500.FIG. 5B illustrates a high level side view of the portion of temporary hardenablematerial construction apparatus 500 ofFIG. 5A .FIG. 5C illustrates a high level perspective view of temporary hardenablematerial construction apparatus 500.FIG. 5D illustrates a high level side view of temporary hardenablematerial construction apparatus 500.FIG. 5E illustrates a high level top view of temporary hardenablematerial construction apparatus 500.FIG. 5F illustrates a high level perspective view of a temporary hardenablematerial construction apparatus 600.FIGS. 5A-5F are described together. Temporary hardenablematerial construction apparatus 500 is in all respects similar to temporary hardenablematerial construction apparatus 300 with the addition of: a plurality of freestandable support frames 510; aceiling panel 520 exhibiting afirst face 521, asecond face 522 opposingfirst face 521, afirst side 523 extending fromfirst face 521 tosecond face 522, asecond side 524 opposingfirst side 523 and extending fromfirst face 521 tosecond face 522, athird side 525 perpendicular tofirst side 523 and extending fromfirst face 521 tosecond face 522, and afourth side 526 opposingthird side 525 and extending fromfirst face 521 tosecond face 522; and a plurality of hardenablematerial securing members 530. For clarity,extension members 40,grid assemblies 310 and securingmembers 320 are not shown. In one embodiment,ceiling panel 520 comprises a drywall panel. Additionally, as illustrated inFIGS. 5C-5D , temporary hardenablematerial construction apparatus 500 comprises fourenclosure members 330 and fourenclosure members 60,space 70 being defined betweeninner faces 52 ofenclosure members 330 andinner faces 62 ofenclosure members 60. - Freestandable support frames 510 are in all respects similar to freestandable support frames 20 and
base portion 26 of eachfreestandable support frame 510 is positioned on top oftop portion 27 of a respectivefreestandable support frame 20 such that freestandable support frames 510 are supported by freestandable support frames 20.Enclosure member 330 extends frombase portions 26 of freestandable support frames 20 totop portions 27 of freestandable support frames 510. -
Second face 522 ofceiling panel 520 is disposed ontop portions 37 of freestandable support frames 30 and onenclosure member 60. Particularly,first side 523 ofceiling panel 520 meets the plane defined byinner face 62 ofenclosure member 60,ceiling panel 520 extending away from freestandable support frames 30. As illustrated inFIGS. 5C and 5D ,ceiling panel 520 is disposed on four rows of freestandable support frames 30. Each of a first set of hardenablematerial securing members 530 extends vertically from withinceiling panel 520 to a point abovefirst face 521. In one embodiment, each hardenablematerial support member 530 extends about 12 centimeters abovefirst face 521. In another embodiment, each hardenablematerial support member 530 is 6-8 millimeters thick. In one embodiment, hardenablematerial securing members 530 are spaced apart from each other at distances of about 60 centimeters. In another embodiment, each hardenablematerial support member 530 comprises a screw. Similarly, each of a second set of hardenablematerial securing members 530 extends horizontally from withinenclosure member 60 to a point withinspace 70, displaced frominner face 62 ofenclosure member 60. In one embodiment, wooden beams, and optionally an additional wooden panel, are disposed betweenceiling panel 520 andtop portions 37 of freestandable support frames 30. - As described above in relation to temporary hardenable
material construction apparatus 400, aspiral staircase 410 is positioned at each corner of the rows of freestandable support frames 20 such that freestandable support frames 510 are easily accessible. -
Hardenable material 80 is poured ontoceiling panel 520.Hardenable material 80, which as described above is a fluid material, such as concrete, spills over first, second, third andfourth sides ceiling panel 520 intospace 70 formed between the foursecond enclosure members 60 and fourenclosure members 330. As a result, four walls and a ceiling are formed as a single block ofhardenable material 80, which gradually hardens. Hardenablematerial securing members 530 are arranged to secureceiling panel 520 and each ofenclosure members 60 tohardenable material 80 after hardening. Advantageously, in the embodiment whereceiling panel 520 andenclosure members 60 each comprise a drywall panel, the drywall panels are directly attached to the hardened hardenable material, without the use of plaster. - After pouring
hardenable material 80, a second floor can be built, as illustrated in temporary hardenablematerial construction apparatus 600 ofFIG. 5F , which represents temporary hardenablematerial construction apparatus 500 afterhardenable material 80 is poured. Particularly, temporary hardenablematerial construction apparatus 600 is in all respects similar to temporary hardenablematerial construction apparatus 500, with the exception that freestandable support frames 30 are replaced with a plurality of freestandable support frames 610. Additionally, anenclosure member 620 is provided. Freestandable support frames 610 are in all respects similar to freestandable support frames 30, with the exception that baseportions 36 of freestandable support frames 610 are positioned on top ofhardenable material 80, overceiling panel 520 and over the location of the previously positioned freestandable support frames 30.Enclosure member 620 is in all respects similar toenclosure member 60, with the exception thatenclosure member 620 is positioned on top ofhardenable material 80, overceiling panel 520 and overenclosure member 60. As described above in relation to freestandable support frames 30,first face 32 of eachfreestandable support frame 30 is juxtaposed withouter face 64 ofenclosure member 620. As described above in relation toenclosure members space 70 is defined betweeninner face 52 ofenclosure member 330 andinner face 62 ofenclosure member 620. A ceiling panel (not shown) can be positioned on top of freestandable support frames 610 andhardenable material 80 can be poured thereon, as described above in relation to temporary hardenablematerial construction apparatus 500. As described above,extension members 40 extend throughenclosure member 330 andenclosure member 620 and are secured to freestandable support frames 510 and freestandable support frames 610. - In another embodiment shown in
FIG. 5G , an innerfreestandable support frame 630 is used to supportceiling panel 520. Temporary hardenablematerial construction apparatus freestandable support frame 630, the other aspects thereof applying with the exception offreestandable support frame 30, mutatis mutandis. - In order to facilitate its removal after
ceiling panel 520 has been formed thereabove, innerfreestandable support frame 630 is configured with separateupper section 632 andlower section 634, which may be identical, albeit oppositely oriented. To each upright 629 ofupper section 632 and to anupright 631 oflower section 634 aligned therewith is positioned in abutting relation, and releasably secured thereto, a correspondingelongated connector 637, which may have a uniform width and be carefully positioned so as not to protrude into the space within which the hardenable material is to be poured. - Inner
freestandable support frame 630 generally, but not necessarily, has the same dimensions asfreestandable support frame 30. For example, a rectilinear innerfreestandable support frame 630 has a height of 270 cm, a longitudinal dimension of 120 cm and a transversal dimension of 60 cm. This height is achievable by providing a void area of 30 cm betweenupper section 632 andlower section 634 and by releasably securingconnector 637 having a length of 30 cm to the upright of bothupper section 632 andlower section 634. As additional means for ensuring the structural strength of innerstandable support frame 630, aninsert 639 is received within the void area in such a way so as to contact and be in force transmitting relation with bothupper section 632 andlower section 634.Insert 639 is releasably connected toconnector 637. - After
ceiling panel 520 has been formed and has hardened, eachinsert 639 is detached from itscorresponding connector 637, after which the fasteners by whichconnectors 637 are secured to a corresponding pair ofuprights section 634,upper section 632 is therefore able to be easily removed from below the ceiling panel. - It will be appreciated that inner
freestandable support frame 630 may be configured with any other number of interconnectable sections. - Although the above has been described in relation to freestandable support frames 20, 30, 510, 610 and 630 this is not meant to be limiting in any way. In another embodiment, freestandable support frames 20, 30, 510 and 610 can be replaced with support frames which are not freestandable without exceeding the scope.
-
FIG. 6A illustrates a high level flow chart of a hardenable material construction method. Instage 1000, a first enclosure member is positioned in parallel with a second enclosure member such that a space is defined between an inner face of the first enclosure member and an inner face of the second enclosure member. Optionally, the second enclosure member is formed of a drywall panel, optionally sealed with a liquid repelling material. - In
stage 1010, a first freestandable support frame is juxtaposed with an outer face of the first enclosure member ofstage 1000 or the outer face of the second enclosure member ofstage 1000. The outer face of the first enclosure member opposes the inner face of the first enclosure member. The outer face of the second enclosure member opposes the inner face of the second enclosure member. First freestandable support frame extends from a first face to a second face, the first face thereof juxtaposed with the outer face of the first enclosure member. Optionally, the distance between the first face and the second face of the first freestandable support frame is about 120 centimeters. Optionally, a plurality of first freestandable support frames are each juxtaposed with the outer face of the first enclosure member, or the outer face the second enclosure member, the plurality of first freestandable support frames arranged in a row. Optionally, the first freestandable support frame exhibits an indentation in the first face thereof, the indentation arranged to receive a protruding portion of the first enclosure member ofstage 1000. - In
optional stage 1020, a second freestandable support frame is juxtaposed with an outer face of the second enclosure member ofstage 1000, the outer face of the second enclosure member opposing the inner face of the second enclosure member. In such an embodiment, the first freestandable support frame ofstage 1010 is juxtaposed with the outer face of the first enclosure member ofstage 1000. Optionally, a plurality of second freestandable support frames are each juxtaposed with the outer face of the second enclosure member, the plurality of second freestandable support frames arranged in a row. - In
stage 1030, at least one extension member is inserted through the first enclosure member and the second enclosure member such that a first end of the at least one extension member extends past the outer face of the first enclosure member ofstage 1000 or a second end of the at least one extension member, opposing the first end thereof, extends past the outer face of the second enclosure member ofstage 1000. - In
stage 1040, the at least one extension member ofstage 1030, optionally the first end thereof, is secured to the first freestandable support frame ofstage 1010. Optionally, a plurality of extension members are each secured to a respective one of a plurality of first freestandable support frames. Inoptional stage 1050, the second end of the at least one extension member is secured to the second freestandable support frame ofoptional stage 1020. Optionally, a plurality of extension members are each secured to a respective one of a plurality of second freestandable support frames. - In
stage 1060, subsequent to the securing the at least one extension member to the first and second freestandable support frame of stages 1040-1050, hardenable material is poured into the space defined between the first enclosure member and the second enclosure member ofstage 1000. - In
optional stage 1070, prior to the pouring hardenable material ofstage 1060, an outer face of an insulation layer is positioned to face an inner face of an outer layer so as to form the first enclosure member ofstage 1000. The outer layer exhibits an outer face opposing the inner face thereof, an outer face of the first enclosure member ofstage 1000, opposing the inner face thereof, comprising the outer face of the outer layer. Additionally, the insulation layer exhibits an inner face opposing the outer face thereof, the inner face of the first enclosure member ofstage 1000 comprising the inner face of the insulation layer. Optionally, the outer face of the insulation layer is positioned to be in direct contact with the inner face of the outer layer. Particularly, no plaster is disposed between the insulation layer and the outer layer. - In
optional stage 1080, a grid assembly is disposed within the defined space ofstage 1000. Additionally, the grid assembly is secured to one of a plurality of the extension members ofstage 1030 so as to separate the grid assembly from the insulation layer ofoptional stage 1070 by at least a predetermined distance. Inoptional stage 1090, the insulation layer is secured to the outer layer with a plurality of securing members, each of the plurality of securing members disposed on a respective one of a plurality of the extension members ofstage 1030. -
FIG. 6B illustrates a high level flow chart of optional stages of forming the first enclosure ofstage 1000 ofFIG. 6A . In stage 2000, a first side of each of a plurality of slabs is positioned to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof. The first side and second side of each of the plurality of slabs exhibit a slit configured to receive a respective one of a plurality of strips. Instage 2010, a respective one of the plurality of strips of stage 2000 is disposed within the slit of the first side of each of the plurality of slabs of stage 2000 and the slit of the second side of the respective another slab. - In
stage 2020, each of a plurality of the extension members ofstage 1030 is inserted through a respective one of a plurality of facade securing elements, the facade securing elements each secured to one of a plurality of facade members. Optionally, each facade member comprises a slab of stage 2000 and each facade securing element comprises a strip ofstage 2010. Optionally, the insertion through the first enclosure member ofstage 1030 is responsive to the insertion through the plurality of facade securing elements. - In
optional stage 2030, each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, is disposed within the slit of the first side of a first of the plurality of slabs of stage 2000 and within the slit of the first side of a second of the plurality of slabs. -
FIG. 6C illustrates a high level flow chart of further optional stages of the hardenable material construction method of stages 1000-1090. Instage 3000, prior to the pouring hardenable material ofstage 1060, a ceiling panel is positioned to be supported by an upper portion of the second freestandable support frame ofstage 1020. Instage 3010, a third freestandable support frame is positioned on top of the first freestandable support frame. Instage 3020, the third freestandable support frame ofstage 3010 is juxtaposed with the outer face of the first enclosure member, the insulation layer of the first enclosure member ofoptional stage 1070 rising above the positioned ceiling panel. Instage 3030, hardenable material is poured onto the ceiling panel, the pouring hardenable material into the space defined between the first enclosure member and the second enclosure member ofstage 1060 responsive to the pouring hardenable material onto the positioned ceiling panel. The hardenable material spills from the ceiling panel into the defined space such that a single block of hardenable material is formed as a ceiling and walls. - In
optional stage 3040, the positioned ceiling panel comprises a drywall panel with a plurality of hardenable material securing members inserted into the drywall panel such that each of the plurality of hardenable material securing members extend from within the drywall panel to a point above a face of the drywall panel. -
FIGS. 7A-7I illustrates various high level views of various stages of construction using a temporary hardenablematerial construction apparatus 700, according to certain embodiments. Particularly,FIG. 7A illustrates a high level perspective view of asupport structure 710 comprising: asupport frame 720; a pair ofextension arms 730, each exhibiting afirst end 732 and asecond end 734 opposingfirst end 732; a pair ofinner support arms 740; and a pair ofouter support arms 750.Support frame 720 comprises: a plurality ofupper arms 760, each exhibiting afirst end 762 and asecond end 764 opposingfirst end 762; a plurality oflower arms 770, each exhibiting afirst end 772 and asecond end 774 opposingfirst end 772; a plurality ofconnection arms 780, each exhibiting afirst end 782 and asecond end 784 opposingfirst end 782; abase portion 790 exhibiting afirst side 792, asecond side 794, athird side 796 and afourth side 798; and atop portion 800 exhibiting afirst side 802, asecond side 804, athird side 806 and afourth side 808. -
Upper arms 760 each extend downwards in a generally vertical direction fromtop portion 800 atfirst end 762 thereof andlower arms 770 each extend upwards in a generally vertical direction frombase portion 790 atfirst end 772 thereof such thatsecond end 764 of eachupper arm 760 facessecond end 774 of eachlower arm 774, with an adjustable space 810 between them.First end 782 of eachconnection arm 780 is secured to a respectiveupper arm 760 and the respectivesecond end 784 is secured to the opposinglower arm 770. In order to adjust the size of space 810, i.e. the distance between second ends 764 ofupper arms 760 and second ends 774 ofupper arms 770,upper arms 760 andlower arms 770 are respectively connected to connectingarms 780 at different points thereof. In one embodiment,base portion 790 is generally rectangular shaped with short opposingsides sides First end 772 of eachlower arm 770 is secured at a respective corner of the generally rectangular shapedbase portion 790. In another embodiment,top portion 800 is generally rectangular shaped with short opposingsides sides First end 762 of eachupper arm 760 is secured at a respective corner of the generally rectangular shapedtop portion 800. In one embodiment, the length of each oflong sides short sides short sides long sides support frame 720 to be freestandable and further allows for two workers to simultaneously be insidesupport frame 720. In one embodiment,support frame 720 is bolted into the floor. - A
first extension arm 730 extends fromside 806 oftop portion 800, atfirst end 732 thereof, and asecond extension arm 730 extends fromside 808 oftop portion 800, atfirst end 732 thereof. In one embodiment,side 806 andfirst extension arm 730 form a single beam andside 808 andsecond extension arm 730 form a single beam. In one embodiment, the length of eachextension arm 730 is no more than 150 centimeters such thatsupport frame 720 can supportinner support arms 740 andouter support arms 750, as will be described below. A firstouter support arm 750 extends downward in a generally vertical direction fromsecond end 734 offirst extension arm 730 and a secondouter support arm 750 extends downward in a generally vertical direction fromsecond end 734 ofsecond extension arm 730. A firstinner support arm 740 extends downward in a generally vertical direction from a predetermined point offirst extension arm 730 and a secondinner support arm 740 extends downward in a generally vertical direction from a predetermined point ofsecond extension arm 730. The distance betweeninner support arms 740 andouter support arms 750 is denoted 820, distance 820 being determined in accordance with the desired wall dimensions, as will be described below. In one non-limiting embodiment, distance 820 is about 30 centimeters. The distance betweeninner support arms 740 andsupport frame 720 is denoted 830. In one embodiment, distance 830 is between 60-120 centimeters, optionally 80-100 centimeters. These distances 830 short enough to allowsupport frame 720 to supportinner support arms 740 andouter support arms 750 and long enough to allow space to work and walk through. - As illustrated in
FIG. 7E , support structure further comprises a plurality of elongated strengtheningarms 840. A first set of strengtheningarms 840 extend from firstinner support arm 740 to supportframe 720 and a second set of strengtheningarms 840 extend from secondinner support arm 740 to supportframe 720, thereby strengthening the connection betweeninner support arms 740 to supportframe 720. In one embodiment, each set of strengtheningarms 840 comprises a plurality of strengtheningarms 840 in a ladder like structure and generally evenly spaced. In another embodiment, strengtheningarms 840 is positioned withinsupport structure 710, i.e. in the space between the pair ofinner support arms 740, such that a plurality ofsupport structures 710 can be positioned flush against each other as illustrated inFIG. 7F . - As illustrated in
FIG. 7B , in a first stage of construction, whereinner support arms 740 and strengtheningarms 840 are not yet provided, afirst strip 120 is secured to the bottom of eachouter support arm 750. Particularly, a plurality ofsupport extension members 850 are provided, each exhibiting afirst end 852 and asecond end 854 opposingfirst end 852. In one embodiment, each support extension member is a bar about 8 millimeters thick. A firstsupport extension member 850 extends through arespective hole 140 offirst strip 120 and is secured to firstouter support arm 750 atfirst end 852 thereof. A secondsupport extension member 850 extends through arespective hole 140 offirst strip 120 and is secured to secondouter support arm 750 atfirst end 852 thereof. In one embodiment,first end 852 is sharpened to allowsupport extension members 850 to be screwed into the respectiveouter support arms 750. In one embodiment, a plastic sheath (not shown) is arranged to cover eachsupport extension member 850 to allow easier extraction ofsupport extension members 850 from hardenable material, as will be described below. Additionally, in one embodiment, a plurality offree extension members 860 are provided, each exhibiting afirst end 862 and asecond end 864 opposingfirst end 862. In one embodiment, eachfree extension member 860 is a bar about 8 millimeters thick.First end 862 of each of a pair offree extension members 860 extend through arespective hole 140 offirst strip 120. In one embodiment, a cap is screwed overfirst end 862 of eachfree extension member 860 so as to remain secured tofirst strip 120. - A
first slab 110 is the positioned over the securedfirst strip 120, withfirst strip 120 disposed withinslit 130 offirst side 113 offirst slab 110, as described above in relation toenclosure member 100 ofFIGS. 2A-21 . Asecond strip 120 is disposed withinslit 130 ofsecond side 114 offirst slab 110 and a pair ofsupport extension members 850 and a pair offree extension members 860 are inserted throughrespective holes 140 ofsecond strip 120, as described above.Slabs 110 and strips 120 are interchangeably positioned over each other, withsupport extension members 850 andfree extension members 860 inserted throughrespective holes 140, until theuppermost strip 120 is adjacent toextension arms 730, as illustrated inFIG. 7C . - As further illustrated in
FIG. 7C , apanel 870 and apanel 880 are provided.Panel 870 exhibits aninner face 872 and anouter face 874 opposinginner face 872.Panel 880 exhibits aninner face 882 and anouter face 884 opposinginner face 882. In one non-limiting embodiment,panel 870 andpanel 880 are each a RAPID composite wall panel commercially available from Green & Easy House Inc. of Rishon Le'tzion, Israel.Outer face 874 ofpanel 870 is positioned againstslabs 110 withsupport extension members 850 andfree extension members 860 extending therethrough such thatpanel 870 andslabs 110 for anenclosure member 890, as described above in relation toinsulation layer 150. Particularly,inner face 874 ofpanel 870 facessupport frame 720.Outer face 874 ofpanel 870 substantially covers all of thestacked slabs 110 and strips 120.Panel 880 is positioned betweenpanel 870 andsupport frame 720 such thatinner face 882 ofpanel 880 facesinner face 872 ofpanel 870 withsupport extension members 850 andfree extension members 860 extending therethrough, thereby forming anenclosure member 900. In one embodiment, the size and shape ofpanels space 70 is thus defined betweenenclosure members inner face 872 ofpanel 870 andinner face 882 ofpanel 880. - As illustrated in
FIG. 7D , first and secondinner support arms 740 are positioned againstouter face 884 ofpanel 880 withsupport extension members 850 extending throughinner support arms 740. In one embodiment, a nut is screwed onto eachsupport extension member 850 such thatinner support arms 740 are secured topanel 880. In another embodiment,inner support arms 740 are each secured to therespective extension arm 730. Thus,enclosure member 890 is juxtaposed withinner support arms 740 andenclosure member 900 is juxtaposed withouter support arms 750. As illustrated inFIG. 7E , elongated strengtheningarms 840 are secured toinner support arms 740 andsupport frame 720, as described above. - As illustrated in
FIG. 7F , a plurality ofsupport structures 710, with therespective slabs 110, strips 120,support extension members 850,free extension members 860,panel 870 andpanel 880, are positioned adjacent to each other such thatpanels 870 form a single panel andpanels 880 form a single panel withspace 70 defined therebetween. As illustrated inFIG. 7G ,hardenable material 80 is poured intospace 70. - As illustrated in
FIG. 7H , afterhardenable material 80 is poured and the pressure applied topanels inner support arm 740 and elongated strengtheningarms 840 are removed. Support extension members are then extracted fromouter support arms 750 and removed fromhardenable material 80. As illustrated inFIG. 7I ,outer support arms 750 are removed. In one embodiment,outer support arms 750 are removed together withextension arms 730. As described above in relation toFIGS. 1-3 , a wall comprised ofhardenable material 80 is sandwiched betweenpanel 880 the combination ofpanel 870 andslabs 110, withfree extension members 860 securingslabs 110, viastrips 120, topanel 870. - Advantageously, temporary hardenable
material construction apparatus 700 allows to construct building walls without the use of cranes, or with limited use thereof, since the walls are constructed utilizing the support of support frames 720 which are inside the building. It is particularly noted that the features of temporary hardenablematerial construction apparatus 700 can be incorporated with the features of temporary hardenablematerial construction apparatuses material construction apparatuses - Although the above has been described wherein a plurality of
free extension members 860 are provided to securepanels strips 120, this is not meant to be limiting in any way. In another embodiment (not shown), strips 120 are secured to a grid assembly, such asgrid assembly 310 described above, optionally by metal wires bent through a pair ofholes 140 and tied to the grid assembly after being inserted throughpanel 870. Similarly,panel 880 is secured to the grid assembly, optionally by bent metal wires being inserted therethrough at at least two points and tied to the grid assembly. -
FIG. 8A illustrates a high level flow chart of a second hardenable material construction method. Instage 4000, an outer face of a first enclosure member is juxtaposed with a first outer support arm. The first outer support arm extends from a support frame. Optionally, the first outer support arm extends across the entirety of the outer face of the first enclosure member. Optionally, the first outer support arm is secured to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the securement to the first extension arm. Instage 4010, a first end of at least one support extension member is secured to the first outer support arm ofstage 4000. - In
stage 4020, a first inner support arm is juxtaposed with an outer face of a second enclosure member. The first inner support arm extends from the support frame ofstage 4000. Optionally, the first inner support arm extends across the entirety of the outer face of the second enclosure member. Optionally, the first inner support arm is secured to a first extension arm extending from the support frame, the extension of the first inner support arm from the support frame responsive to the securement to the first extension arm. Optionally, the distance between the support frame and the second enclosure member is 60-120 centimeters, further optionally 80-100 centimeters. Instage 4030, a second end of the at least one support extension member ofstage 4010 is secured to the first inner support arm ofstage 4020. - In
stage 4040, subsequent to the securing ofstages stage 4000 and the inner face of the first enclosure member ofstage 4020. The secured at least one support extension member ofstages - In
optional stage 4050, prior to the placement of hardenable material ofstage 4040, a second outer support arm and a second inner support arm are each secured to a second extension member which extends from the support frame ofstage 4000. The at least one support extension member comprises a plurality of support extension members. A first end of a first support extension member is secured to the first outer support arm ofstage 4000. A first end of a second support extension member is secured to the second outer support arm. A second end of the first support extension member is secured to the first inner support arm ofstage 4020. A second end of the second support extension member is secured to the second inner support arm. - In
optional stage 4060, prior to the placement of hardenable material ofstage 4040, elongated strengthening arms are each secured between the first inner support arm ofstage 4020 and the support frame ofstage 4000. - In
optional stage 4070, prior to the placement of hardenable material ofstage 4040, a plurality of free extension member are extended through the first enclosure member ofstage 4000 and the second enclosure member ofstage 4020. The free extension members are not secured to either the first outer support arm ofstage 4000 or the first inner support arm ofstage 4020. - In
optional stage 4080, an insulation layer is secured to an outer layer of the first enclosure member ofstage 4000, with securing members each disposed on a respective free extension member ofoptional stage 4070. Inoptional stage 4090, prior to the placement of hardenable material ofstage 4040, a grid assembly is disposed within the defined space ofstage 4040. The grid assembly is further secured to a free extension member ofoptional stage 4070 so as to separate the grid assembly from the insulation layer ofoptional stage 4080 by at least a predetermined distance. -
FIG. 8B illustrates a high level flow chart of optional stages of forming the first enclosure ofstage 4000 ofFIG. 8A . Instage 5000, a first side of each of a plurality of slabs is positioned to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof. The first side and second side of each of the plurality of slabs exhibit a slit configured to receive a respective one of a plurality of strips. Instage 5010, a respective one of the plurality of strips ofstage 5000 is disposed within the slit of the first side of each of the plurality of slabs ofstage 5000 and the slit of the second side of the respective another slab. - In
stage 5020, the at least one support extension member ofstage 4010 is inserted through a respective one of a plurality of facade securing elements, the facade securing elements each secured to one of a plurality of facade members. Optionally, each facade member comprises a slab ofstage 5000 and each facade securing element comprises a strip ofstage 5010. Optionally, the extension of the at least one support extension member through the first enclosure member ofstage 4040 is responsive to the insertion through the respective facade securing element. - In
optional stage 5030, each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, is disposed within the slit of the first side of a first of the plurality of slabs ofstage 5000 and within the slit of the first side of a second of the plurality of slabs. - It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
- Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein.
- All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the patent specification, including definitions, will prevail. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
- The terms “include”, “comprise” and “have” and their conjugates as used herein mean “including but not necessarily limited to”.
- It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
Claims (24)
1. A temporary hardenable material construction apparatus comprising:
a support structure comprising a support frame, a first inner support arm extending from said support frame and a first outer support arm extending from said support frame;
at least one support extension member, said at least one support extension member exhibiting a first end and a second end opposing said first end;
a first enclosure member exhibiting an inner face and an outer face opposing said inner face; and
a second enclosure member exhibiting an inner face and an outer face opposing said inner face, said second enclosure member positioned in parallel with said first enclosure member such that a space is defined between said inner face of said first enclosure member and said inner face of said second enclosure member,
wherein said first outer support arm is juxtaposed with said outer face of said first enclosure member,
wherein said first inner support arm is juxtaposed with said outer face of said second enclosure member,
wherein said at least one support extension member extends through said first enclosure member and said second enclosure member such that said first end of said at least one support extension member extends past said outer face of said first enclosure member and said second end of said at least one support extension member extends past said outer face of said second enclosure member, and
wherein said first end of said at least one support extension member is secured to said first outer support arm and said second end of said at least one support extension member is secured to said first inner support arm.
2. The apparatus of claim 1 , wherein said support structure further comprises a first extension arm extending from said support frame, said extension of said first outer support arm from said support frame responsive to said first outer support arm being secured to said first extension arm and said extension of said first inner support arm from said support frame responsive to said first inner support arm being secured to said first extension arm.
3. The apparatus of claim 2 , wherein said support structure further comprises a second extension arm extending from said support frame, a second inner support arm secured to said second extension arm and a second outer support arm secured to said second extension arm, and
wherein said at least one support extension member comprises a plurality of support extension members, said first end of a first of said plurality of support extension members secured to said first outer support arm, said first end of a second of said plurality of support extension members secured to said second outer support arm, said second end of said first of said plurality of support extension members secured to said first inner support arm and said second end of said second of said plurality of support extension members secured to said second inner support arm.
4. The apparatus of claim 1 , wherein said support structure further comprises a plurality of elongated strengthening arms, each exhibiting a first end and a second end opposing said first end, and
wherein said first end of each of said plurality of elongated strengthening arms is secured to said first inner support arm and said second end of each of said plurality of elongated strengthening arms is secured to said second inner support arm.
5. The apparatus of claim 1 , wherein the distance between said support frame and said second enclosure member is 60-120 centimeters.
6. (canceled)
7. The apparatus of claim 1 , further comprising a plurality of free extension members, each of said plurality of free extension members exhibiting a first end and a second end opposing said first end,
wherein each of said plurality of free extension members extends through said first enclosure member and said second enclosure member, and
wherein said first end of each of said plurality of free extension members is not secured to said first outer support arm and said second end of each of said plurality of free extension members is not secured to said first inner support arm.
8. The apparatus of claim 1 , wherein said first inner support arm extends across the entirety of said outer face of said second enclosure member, and
wherein said first outer support arm extends across the entirety of said outer face of said first enclosure member.
9-14. (canceled)
15. A structure comprising:
a plurality of extension members, each of said plurality of extension members exhibiting a first end and a second end opposing said first end;
a first enclosure member exhibiting an inner face and an outer face opposing said inner face; and
a second enclosure member exhibiting an inner face and an outer face opposing said inner face, said second enclosure member positioned in parallel with said first enclosure member such that a space is defined between said inner face of said first enclosure member and said inner face of said second enclosure member, said space filled with a wall layer of hardenable material;
wherein each of said plurality of extension members extends through said first enclosure member and said second enclosure member, and
wherein said first enclosure member comprises:
a plurality of facade members; and
a plurality of facade securing elements, each of said plurality of facade securing elements secured to a perimeter of a respective one of said plurality of facade members,
wherein each of said plurality of extension members extends through a respective one of said plurality of facade securing elements.
16. The structure of claim 15 , wherein each of said plurality of facade securing elements comprises a strip,
wherein each of said plurality of facade members comprises a slab, each of said plurality of slabs exhibiting a first face, a second face opposing said first face, a first side extending from said first face to said second face and a second side opposing said first side, each of said first side and said second side exhibiting a slit therealong, said slit configured to receive a respective one of said plurality of strips, and
wherein said first side of each of said plurality of slabs faces said second side of another of said plurality of slabs, a respective one of said plurality of strips disposed within said slit of said first side of said respective slab and within said slit of said second side of said another respective slab, each of said plurality of extension members extending through a respective one of said plurality of strips.
17. The structure of claim 16 , further comprising a plurality of L-shaped corner members, each of said L-shaped corner members exhibiting a first end and a second end perpendicular to said first end, said slit of each of said plurality of slabs further configured to receive one of a first end and a second end of a respective one of said plurality of L-shaped corner members, wherein said at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, said first end of each of said plurality of L-shaped corner members disposed within said slit of said first side of a respective one of said plurality of slabs of a first of said pair of first enclosure members and said second end of each of said plurality of L-shaped corner members disposed within said slit of said first side of a respective one of said plurality of slabs of a second of said pair of first enclosure members.
18. The structure of claim 15 , wherein said first enclosure member comprises:
an outer layer exhibiting an inner face and an outer face opposing said inner face, said outer face of said first enclosure member comprising said outer face of said outer layer, said outer layer comprising said plurality of facade members and said plurality of facade securing elements; and
an insulation layer exhibiting an inner face and an outer face opposing said inner face, said inner face of said insulation layer facing said inner face of said second enclosure member, said outer face of said insulation layer facing said inner face of said outer layer.
19. The structure of claim 18 , wherein said outer face of said insulation layer is in direct contact with said inner face of said outer layer.
20. The structure of claim 18 , further comprising:
a grid assembly disposed within said hardenable material;
a plurality of securing members, each of said plurality of securing members disposed on a respective one of said plurality of extension members and juxtaposed with said insulation layer to secure said insulation layer to said outer layer; and
wherein said grid assembly is secured to one of said plurality of extension members so as to separate said grid assembly from said insulation layer by at least a predetermined distance.
21. The structure of claim 15 , further comprising:
a ceiling panel positioned over said second enclosure member; and
a ceiling layer of hardenable material disposed on said ceiling panel, said insulation layer of said first enclosure member rising above said ceiling layer of hardenable material.
22. A hardenable material construction method, the method comprising:
juxtaposing an outer face of a first enclosure member to a first outer support arm, the first outer support arm extending from a support frame;
securing a first end of at least one support extension member to the first outer support arm;
juxtaposing a first inner support arm to an outer face of a second enclosure member, the first inner support arm extending from a support frame;
securing a second end of the at least one support extension member to the first inner support arm; and
subsequent to said securing the at least one support extension member to the first inner support arm, placing hardenable material into the space defined between an inner face of the first enclosure member and an inner face of the second enclosure member, the inner face of the first enclosure member opposing the outer face of the first enclosure member and the inner face of the second enclosure member opposing the outer face of the second enclosure member,
wherein said secured at least one support extension member extends through the first enclosure member and the second enclosure member.
23. The method of claim 22 , further comprising, prior to said placing:
securing the first outer support arm to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to said securing; and
securing the first inner support arm to the first extension arm, the extension of the first inner support arm from the support frame responsive to said securing.
24. The method of claim 23 , wherein the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to said placing:
securing a second outer support arm to a second extension arm extending from the support frame; and
securing a second inner support arm to the second extension arm,
wherein the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of said plurality of support extension members secured to the second inner support arm.
25. The method of claim 22 , further comprising, prior to said placing:
securing a first end of each of a plurality of elongated strengthening arms to the first inner support arm; and
securing a second end of each of the plurality of elongated strengthening arms to the support frame.
26-27. (canceled)
28. The method of claim 22 , further comprising, prior to said placing, extending a plurality of free extension members through the first enclosure member and the second enclosure member,
wherein said extended free extension members are not secured to said first inner support arm or to said first outer support arm.
29. The method of claim 22 , wherein the first inner support arm extends across the entirety of the outer face of the second enclosure member, and
wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member.
30-35. (canceled)
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US2680894A (en) * | 1951-01-19 | 1954-06-15 | O'sullivan Eugene | Shuttering for use in the construction of chimneys and other structures |
US3664630A (en) * | 1970-06-19 | 1972-05-23 | Symons Mfg Co | Concrete wall form liner |
US20020121586A1 (en) * | 1999-01-13 | 2002-09-05 | Gates H. Gordon | Gang form for use with a concrete form system and method of building a gang form |
US6240700B1 (en) * | 1999-10-12 | 2001-06-05 | Chyi Sheu | Constructing method for underground continuous double-row walls and the structure of continuous double-row walls |
US20050218291A1 (en) * | 2003-01-07 | 2005-10-06 | Dayton Superior Corporation | Concrete wall form with flexible tie system |
US8011637B2 (en) * | 2007-06-15 | 2011-09-06 | Precise Forms, Inc. | Concrete form system for low-clearance applications |
US20130074432A1 (en) * | 2011-09-28 | 2013-03-28 | Romeo Ilarian Ciuperca | Insulated concrete form and method of using same |
US20140265027A1 (en) * | 2013-03-15 | 2014-09-18 | Kenneth Robert Kreizinger | Scaffold Forming System |
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