US2111577A - Concrete construction - Google Patents

Description

March 22, 19318. L. H. THoMAs 2311,57

I CONCRETE CONSTRUCTION Filed Nv. 22, 193s V :s sheets-sheet 1 /A/vE/VTOR 1' LEONARD H. TH arms BY #my M @my O ArroR/VEX March 22, 1938. L.; H. THOMAS CONCRETE CONSTRUCTION File@ Nov. 22, 1955 3 'Sheets-Sheet 2 INVENTOR. LEONARD H. Flo/*ms A TTORNEY March 22, 193s. H, THOMAS l 2,111,577

CONCRETE CONSTRUCTION Filed Nov. 22, 1955 sheets-sheei 3- my n ym 7 ATTORNEY.

Patented ManZZ, 1938 j I l' i .l i

-. UNITED STATES PATENT OFFICE i A y 2,111,517

coNcaE'rE coNs'raUcrIoN Leonard n.. Thomas, oakland, cam. Application November 22,4933, Serial No. 699,161 A 4 claims (ci. 25-*121i I The invention relates to precast wall slabs, and Figure '11 is a section at I I--i I in Figure 9. the associated assembly of such slabs in a un- Figure 12 is a perspective view of an interlocktary structure.4 ing means as operative between adjacent com- An object of the invention is the provision of a pleted slabs. generally improved and particularly eifective Figure 13 is a vertical. section througha com- 5 means for precasting concrete wall slabs in a pleted jointure between adjacent slabs. prone position. Figure 14 is a section at M-M in Figure 13.

Another object is to provide for a casting of As illustrated in the fragmentary view of Figthe slabs in the same relation which they are ure 2, kthe present invention concerns the prol10 tohave in their final assembly, whereby to induction and assembly of intermediate wall slabs 10 sure their subsequent mutual tting at their I6 and complementary corner wall slabs Il and jointures. I8. The slabs are cast of concrete and are cored A further object is to provide precast and cored out from what may be conveniently termed their wall slabs having one side finished in the mold inner faces to deiine intersecting ribs I9 and 20 i5 and the other side provided with means to faciliwhich provide the requisite transverse stiifness 15 tate the fixing of-a facing finish thereto. and4 effective thickness for the slabs while pro- Yet another object is to provide an improved viding slabs of minimum weight. The ribs I9 reinforcing means for a slab. said means inclndprovide the equivalent of studding in the slabs, ing the aforesaid means for use in fixing a facing the upper and lower ribs 2u comprise base and 'to a slab side. head plates for the slabs, and the intermediate An added object is to provide a generally imn ribs 2D provide a cross-bracing between the ribs proved jointure at the abutting side edges of slabs I9 and carry elements for connecting adjacent in a structure formed therewith. slabs in an assembly thereof. Suitable reinforce- A Still further Object is to prei/ide generally ment is provided within the ribs I9 and 2li, and

improved methods for accomplishing certain of wooden furring strips 2l are shown as provided 25 the fOreSOiDg Objects# at and along the inner faces of the ribs i9.

The invention possesses other objects and feai For casting the slabs it and il and I8 -as tures of advantage, some of which, with the foreshown and described, an horizontal and elongated going. Will be Sel; forth 0r be apparent in the molding platform is provided, said platform parfollowing description of a typical embodiment of ticularly shown in'Figures 1 and 3 as comprising 30 the inVeIitiOf. and in the aeeempenyng dl'wjoists 22 supporting deck boards 23 thereacross ings. in which. Y and carried by and between side beams 24. Per- Figure 1 is a fragmentary perspective view marient coremembers 25 are utilized in dening illustrating a mold for use in the casting of wall. molds for the slabs; as particularly shown, the

slabs in accordance with the present invention. core members 25 are tray-like in structure and 35 Figure 2 is a. fragmentary perspective view generally rectangular in outline, and are adapted showing an assembly ofewall slabs embodying the for inverted application on and over the deck invention. f boards 23 with their open sides down. To facili- Figure 3 is an enlarged fragmentary section tate its removal from a cast slab, each core memtaken generally at the line 3-3 in Figure 1. and ber 25 is preferably formed with' appropriately 40 thrOllBh a finished slab on the casting deck. tapering outer sides whereby the ribs produced Figure 4 is a fragmentary perspective view between opposed said sides of adjacent members teken generally at l-- in Figure 3 and Showing in the mold are narrowest at their free edges and a reinforcing'means of the slab. the core members are `freely removablein a well 45. Figure 5 is an enlarged section at 5--5 in Figunderstood manner. 45 l' ure 4. l For providingamold on the deck of the plat- Figure 6 is a perspective View Similar t0 Figform, the furring strips 2l are disposed flat thereure 4, and discloses a modification of the reinon and as spacers between core members 25 in forcing means. a desired arrangement thereof whereby only the Figure 7 is a section at 1--1 in Figure 6. surface portions of the members above the strips 50 y Figure 8 is a. fragmentary face view of a comthereat are exposed-'as bottom mold wall portions. bination partition and core member of the mold. Vertical side plates 26 are disposed on the mold Figure 9 is a section at 9`9 in Figure. deck and define the mold boundaries with their Figure 10 is a fragmentary perspective view of top edges defining a reference plane for the up- 55 the assembly of core elements shown in Figure 8.,( per ieee Qi a Casting vin the meld Form bleks 55 Cil 21 are engaged with and between adjacent members 25 and between the strips 2|, and other blocks 28 are engaged between the side plates 26 and the sides of the members 25 nearest thereto whereby the upper faces of the strips 2| and the blocks 21 and 28, and the exposed side and top faces of the members 25 together, and solely, define the bottom of the moldspace provided for the casting of a slab. The blocks 21 and l2|! are preferably, though not necessarily, of the same thickness as the strips 2|, and the latter may, on occasion, be referred to as mold members without reference to their possible use as furring strips.

It will be understood that the elements 2|, 25, 21 and 23 which cooperatively define a mold bottom are each mutually engaged against the laterally adjacent said, elements whereby a tight mold bottom is provided, it being noted that all of these elements are supported and held positioned on the molding floor provided by the deck boards 23 without being attached to said boards, and are therefore free for any necessary adjustment. in an assembly thereof. In lieu of one or more members 25, a frame for a wall opening may be disposed on the casting deck for keyed fixing f in the finished slab; in the present instance, a window frame 29 is shown as set into a slab I8 which has been cast in the mold space.

The strips 2| are secured to and mount reinforcement assemblies which are arrQanged for desired disposal in each line of spaces between adjacent rows of core members 25 in which a rib I9 of a slab is to be cast. As disclosed in detail in Figures 2 to 5 inclusive, the aforesaid reinforcement comprises spaced and mutually parallel bars 3| and 32 connected byspaping rods 33 secured thereto. Metallic blocks 34 are secured to each lower bar 32 at spaced points therealong, and means are provided to releasably secure the blocks 34 of a bar 32 to a strip 2|. As shown, the blocks 34 comprise nuts threadedly receiving the shanks of screws 35 extending through and upwardly from the strip 2| in its center line. Preferably, and as shown, the bars 3| and 32 lie in a plane which includes the center line of the strip 2|, and is perpendicular to the lower strip face. It will be noted that the blocks 34 are operative as a means forspacing the bar 32 from the mold strip which carries it.

Upper end portions 33 of the upright'spacing rods 33may extend above the bars 3| whereby these portions may be bent downwardly over and about reinforcing rods 31 laid across the bars 3| for a slab, it being noted that the plane defined by the bars 3| lies above the tops of the core members 25 and below the plane defined by the top edges of the side plates 25 whereby the ba'rs 3| and rods 31 may lie within the outer wall portion of the cast slab. Preferably, and as Vindicated ln Figures 4 and 5, the blocks 34 are welded tothe bars` 3l and 32, whereby to provide a unitary reinforcement assembly. 'I'he foregoing reinforcement assembly is designed to be plant manufactured in strips which maybe cut to length whereby only the wooden strips 2| need be thereafter fixed thereto for preparing them for installation in the mold.

An alternative reinforcement assembly is illustrated in Figure 6 wherein bars 4| and 42 are held in mutually spaced relation by reason of their engagement in spaced eyes provided in spacer elements 43 which are formed by twisting a pair of wire strands 44 about the properly spaced bars. The lower end portions f the Strands 44 are driven into opposite sides of a strip 2|', and a cross-rod 36' of the reinforcement may be tied in place on a bar 4| by twisting a piece of wire about the members at their point of mutual crossing. It will be understood that the strip 2| and the rod 36' respectively correspond to the elements 2| and 36 of the previously described reinforcement assembly. The present type of reinforcement assembly may also be manufactured as a stock factory product for use in the disclosed manner. Y

Means are provided for directly securing adjacent wall slabs together in a structure formed therewith, a preferred jointure for mutually coplanar slabs being disclosed in detail in Figures l2 to 14 inclusive. As illustrated, the adjacent wall slabs I6 and I3 are slightly spaced in the assembly and tie bars and 52 extend from the exposed edges of the respective slabs for interlocking in the space defined between the slab ends. The protruding ends of the bars 5| and 52 provide loops 53 which are vertically aligned for receiving a locking bar 54 transverselythrough the loops in a mannerto thereafter prevent a separation of the slabs in their plane. Preferably, and as shown, the bars 5| and 52 are intermediately doubled to provide U-shaped loops at their bends to provide the eyes 53 and to have the remaining portions thereof embedded and anchored in the slabs at the ribs 20 thereof as a reinforcement for the ribs. The tie bars 5| and 52 and the'locking bar 54 are advantageously of square section, as is shown.

It will now be noted that the bars 5| and 52 are arranged in generally aligned pairs whereby the eye loops 53 of a pair of bars are close together and mutually parallel. When the bar 54 is engaged against the inside end face 55 of one eye loop, it is arranged to be spaced from the inside end face v55 of the other eye loop of the pair, and wedge means are provided for coaction b etween the latter end face and the bar 54 to forcibly engage the bar with the end face of the first loop and so secure the loops againsta separation thereof and of the slabs which carry them. As particularly shown, the aforesaid wedge means comprises a wedge 56 for engagement against the loop face 55 not engaged by the bar 54, and a block 51 engaged between the wedge and bar.

. wedges 58 are applied for fixing the slabs together along their mutually abutting edges. Preferably, and as shown, each loop 53 which is to be directly engaged by a wedge 56 is slightly curved toward the companion loop of a loop pair whereby theflat outer 'wedge face may engage flat against the opposed loop face 55. The bar 54 is large enough to be relatively stiff against flexure whereby to minimize the effect of the mutually offset coaction of each pair of loops 53 therewith.

It will now be noted that the slab edges at the loops 53 are formed to provide grooves 58 along ltheir lengths, and that each said groove is deepened at portions 59 thereof opposite the outer ends of the loops 53 which extend theretoward from the opposed slab edge whereby to freely receive said loop endsin said groove portions. The opposed slab ends are otherwise, and correspondingly, so shaped that they are but slightly spaced adjacent the outer slab faces, and are so spaced at and inwardly of the loops 53 as to permit an operative disposal of the wedges 58 from the inner side of the slab assembly.

When adjacent slabs are mutually-interlocked along their opposed edges by the described means, the outer and narrow portion of the space'be-` 4 tween the slab ends is filled with concreteto a flush relation with the outer slab faces whereby to conceal the jointure at the latter. Subsequently, a form board-(not shown) is placed at the inner'side of said space and the remainder of the space is filled with self-setting concrete whereby a lling and sealing mass 60 is provided between the slab ends and between the wall faces. It is noted that the mass 60, through its extension into lock of the slabs.

In order to insure uniformity rof jointure and external finish for abutting slabs in an erected straight course or line thereof, the slabs are preferably cast in the same order and relation which they are to have when they are associated as parts of a continuous structure. Accordingly, the casting deck or floor is elongated laterally of the slabs to be cast thereon whereby a succession of slabs may be produced in the order in which they are to be finally assembled. By reference to the fragmentary showing of Figure 1, it will be noted that adjacent molds are provided in which to cast a slab it 'and a slab 'it in the sameedge-to-edge relation and approximate spacing which the slabs vare to have when they are erected, said molds de'ned' at their opposed ends by the opposite faces of a. core member tl which partitions `the mold box within the side plates 2t whichdefine opposite and mutually parallel edges of the molding space.

The core member 6i is seen to be shaped as the space which is to be occupied by a filler mass til when the wall is completed in place, and extends from the deck plane to the plane defined at the top edges of the plates 24. As'particularly brought out in Figures 3, 8, 9 and l0, the member Si essentially comprises acentral plate element 62 extending for the full core width and having plates t3 and t@ fixed to and extending gen# erally centrally along the plate 62 at opposite sides thereof and in alternate arrangement on each side, the plates 63 and 64 being approximate- J ly one third as wide as theplate t2 between them.

When themember tl is installed on the mold deck, the lower edge of the element G2 is engaged between the spacer strips 65 which in turn laterally engage strips 2| carrying the described assemblies of rib reinforcement; vin this manner, the slabs cast in -molds at opposite sides of a core or partition 6| are produced in the rela.- tive relation which they are to have when erected in a structure. At that side of the plates 83 and 64 which is toward the upper mold face; the plate 62 is tapered to a relatively narrow edge to provide the previously ldescribed narrow portion of the space between opposed slab ends.

In order that the core member 6I may receive the tie bar loops 53 within the space thereof, the central core element l! is provided with interior slots 68 for receiving the pairs of loops 63 therein and therethrough. As particularly brought out in Figures 8 to 1i inclusive, the plates M are generally U-shaped and are fixed and disposed on the element 62 to receive the extremities of the loops within" their openings 61. 'Ihe plates 6I at the cooperating pair of loops 53 are disposed at opposite sides of the element 62 and are oppositely directed with their open ends each receiving a loop 53. Y

A somewhat-Z-shaped metallic strip 68 ispdisposed with its central portion between the loops of a pair, and its end portions are-xed to the different plates 64 thereat for closing the outer sides of the openings 61, it being noted that the plates lext'end to the central strip portion and that the width of the strip is that of the slot 66 and opening 61 through which it transversely extends. The plates 63 extend between successive plates 64 at each side of the element t2 and are i notched out at their appropriate extremities for extension through the loop thereat. Preferably, and as shown, the plates 64 are somewhat thicker than the plates $3 transversely ofthe element 62 lvsrl'lereby the former plates areoperative as a ,core means to denne the enlarged portions t@ of the slab grooves 58, while the plates t3 dene the remaining portions of said grooves.

It will be understood that the described core assembly 6l vis designed to completely enclose the pairs of loops of the tiebars therein whereby the loops may extend from the cast slabs when the core assembly is removed. The assembly of the element-62, plates tt and metal strip 6B, may be permanent, and when such assembly is placed in the described position on the casting deck. the

tie'bars 5i and 52 may be placed in the moldwith their loops extending into the core space therefor. When the tie bars have been placed, the plates 63 may be applied in their operative positions, this application of the plates 6d positioning and securing the loops as required. lWhen the slabs have been cast in adjacency in the completed molds, they may ,be separated in their plane to free the'partition core El. it being noted that the plates 63 will simultaneously be pulled from their engagement with the element 62 with the slabs and for subsequent removal from the slabs.

Since thev slab l@ is a corner wall slab and is arranged for connection with a. slab il for providing a corner at their mutual jointure, the corner-defining edge of this slab is appropriately bevelled for coaction with a complementary bevelled edge of the slab il. As shown in Figures 2 and 3, the said edge is arranged to make a forty-five degree angle with the plane of the slab and is otherwise formed generally as the other end face of the slab. For defining said bevelled face of the slab I8, a mold member H is provided at the mold end, said member comprising a plate element l2 set at an appropriate angle to the mold bottom and carrying on its inner face plate elements which correspond to the elements t3 and 6I ofthe core member 6I. Bars 'it which provide loops 63' for use ln interlocking corner slabs are so bent at said loops that the outer loop ends are parallel to the`plane of the element 12, the

arrangement' permitting the use of a locking bar 54 and wedges 56 as at the other jointures.V

Having the molds completed through the appropriete placement of the described mold and reinforcement and tyingbars, the molds are filled to the level of the tops of the side Vplates 2,8 with a suitable self-setting concrete in a plastic state. Preferably, and as particularly indicated, the exposed slab faces 'I9 would be finished as a nal surface for the slab thereat. this being made possible by reason of the horizontal position of such face of the mold andthe top edges of the plates 26 providing a screeding plane for use in applying a finish to the faces 19. With slabs so completed, their finished faces 19 may provide the outer facing of a building thereof without further labor. The various slabs in the described mold would preferably have their upper faces nished together and with the same batch of grouting or other finish whereby the faces thereof may have a like appearance in the final structure. In the present instance, the mold plates 26 at the top of a cast wall slab are arranged to remain on the slab, being secured thereto by means of anchor rods 8l fixed therein and embedded in the slab.

When the present slabs are erected in place, the strips 2l may be used as a furring backing for a suitable surface finish applied thereto, or may be removed by unscrewing the screws 35. If the strips 2l are removed, the screws 35, or other screws, may be used to fasten other elements to the embedded and xedly secured blocks 34 of the reinforcement assembly for each rib I9.

It will be understood that the described precasting of slabs in an horizontal position and in a mold such as that now described facilitates the placement of the plastic concrete in the mold, the production of uniform concrete structures, and the production of slabs with one nished face; all with the use of a minimized amount of form material and labor. Furthermore, the various features of the disclosed interlock and keying of adjacent slabs in a structure is generally .applicable to horizontally disposed slabs as well as to "the upright wall slabs'particularly shown.' From the foregoing description, taken in con-- nection with the accompanying drawings, the advantages of the construction and the means for producing the same will be readily understood by those skilled in the art to which the invention appertains, and while I have described the principle of operation, together with the devices which I now consider to be preferred embodiments thereof, I desire to have it understood that the devices shown and described are merely illustrative, and that such changes may be made, when desired, as fall within the scope of the appended claims.

Having thus described im' invention, I claim as new and desire to secure by Letters Patent of the United States the following:

1. In combination with a mold comprising form boards defining a mold space for the casting of a concrete body, a. pre-assembled metallic reinforcement disposed intermediately in the mold space to extend along a said form board and including a bar, metallic spacing members fixed to and along said bar in integral relation thereto and engaged against the said form board, and means securing the members to the said form board.

2. In combination with a mold for casting a concrete slab to have a cored face and including free core members disposed on a supporting surface for defining ribs of said slab face between them and free form boards disposed on said surface in lateral engagement with said core members whereby the core members are mutually spaced and the upper faces of said boards and the face portions of the core members above the level of said upper board faces solely define the cored face of a slab cast in said mold, a planar metallic reinforcement assembly disposed in a ribdefining portion of the mold space for embedment in a rib of the slab, spacer blocks integrally fixed to the lower edge of said reinforcement assembly. and means coactive between the blocks and a said form board releasably securing the board in fixed relation to the reinforcement.

3. In combination with means defining a mold space divided to provide portions thereof for the production of a plurality of separate slabs in the space and in the order of their erection, said means including a form element fully partitioning said space at the line of abutment of adjacent mold portions and operative as a core member to provide longitudinally grooved slab edges Vthereat whereby the grooves of the adjacent slab edges are cooperative to provide an open keying space between the slabs when the completed slabs are reassociated in the relation of their casting, means providing a cavity in said element, and mutually free metallic tying members extending from the slab spaces into said cavity from both sides thereof for a fixing together of their free ends in the aforesaid space between the slab edges when the completed slabs are reassociated.

4. Ina mold providing a mold space divided to provide portions thereof for the production therein of separate slabs in the space and in the order of their erection, a form element fully partitioning said space at the line of abutment of adjacent mold portions and operative as a core member to provide recessed slab edges thereat whereby the recesses of the adjacent slab edges provide keying spaces between the slab ends when the completed slabs are reassociated in the relationship of their casting, means providing a cavity in said element, and mutually free metallic tying members extending from adjacent slab spaces into said cavity for a xing together of their free ends in a keying space between the slab edges when the completed slabs are reassoclated.

LEONARD H. THOMAS.

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