US3676975A

US3676975A - Apparatus for the construction of concrete structures

Info

Publication number: US3676975A
Application number: US53803A
Authority: US
Inventors: Anthony W Belluscio
Original assignee: Individual
Current assignee: Individual
Priority date: 1970-07-10
Filing date: 1970-07-10
Publication date: 1972-07-18
Anticipated expiration: 1989-07-18

Abstract

A concrete structure, e. g. a dwelling house, is disclosed to include a base slab, a monolithic divider slab for defining an outside wall and a plurality of interior walls, and a concrete roof. The monolithic divider slab encases conduits for providing electrical service and suitable piping means for providing plumbing services. The structure is disclosed to be constructed by pouring a base slab on the desired site, erecting a form on the base slab after curing to define an opening for concrete for the monolithic divider slab, filling the opening so defined with concrete and allowing it to cure, removing the forms and positioning a precast concrete roof on and in secure engagement with the monolithic divider slab. The roof may be poured conveniently adjacent the base slab site and thereafter lifted into position on the monolithic divider slab. Where the roof is in sections, a novel sealing structure is disclosed for securing the joint at the interface of the sections. Also disclosed is a novel form arrangement and structure which utilizes sectionalized and pivotally related form sections to accommodate the pouring of the monolithic divider slab as a single pour and to enable the set-up, knock-down and transportation of the forms with a minimum of difficulty.

Description

United States Patent Belluscio 1 July 18, 1972 [72] Inventor: Anthony W. Belluaclo, l6ll E. Elizabeth Ave, Linden, NJ. 10453 qsn |m.c| ..E04bI/00 5s FleldotSearch ..52 741.743,745.238

[56] References Cited UNITED STATES PATENTS 4/1967 Smith ..52/743 9/l968 Comment 7/1969 Rice ..52/743 Primary Examiner- Patrick D. Lawson Attorney-Popper, Bain, Bobis & Gilfillan [57] ABSTRACT A concrete structure, e. g. a dwelling house, is disclosed to include a base slab, a monolithic divider slab for defining an outside wall and a plurality of interior walls, and a concrete roof. The monolithic divider slab encases conduits for providing electrical service and suitable piping means for providing plumbing services.

The structure is disclosed to be constructed by pouring a base slab on the desired site, erecting a form on the base slab after curing to define an opening for concrete for the monolithic divider slab, filling the opening so defined with concrete and allowing it to cure, removing the forms and positioning a precast concrete roof on and in secure engagement with the monolithic divider slab. The roof may be poured conveniently adjacent the base slab site and thereafter lifted into position on the monolithic divider slab. Where the roof is in sections, a novel sealing structure is disclosed for securing the joint at the interface of the sections.

Also disclosed is a novel form arrangement and structure which utilizes sectionalized and pivotally related form sections to accommodate the pouring of the monolithic divider slab as a single pour and to enable the set-up, knock-down and transportation of the forms with a minimum of difficulty.

5 Claims, 10 lh'awing Figures PATENTEnJuu 81912 3.678; 975 SHEET 1 OF 5 FIG. 2 l0 m/vavrox? ANTI-ION) W BELLUSC/O By POPPER, 54w, 808/5 a GIL F/LLA/V ATTORNEYS PATENTEU .wu 81972 SHEET 30F 5 PATENTEB JUL I 8 I972 SHEET 5 OF 5 APPARATUS FOR THE CONSTRUCTION OF CONCRETE STRUCTURES BACKGROUND OF THE INVENTION One of the principal aims of governments the world over, those engaged in the housing industry, and those concerned with social reform, is the development of satisfactory low cost housing.

Many attempts have been made to develop a building structure which is low in cost and suitable for use as a dwelling house. Included among the proposals have been assembly of the structure from pre-cast concrete sections, prefa brication of the structure at a plant and assembly at the site, and total fabrication of the building structure at an off-site location and transfer to the site. Although each of the foregoing has been successful to some extent, none has provided a low cost structure which is (a) physically large enough to accommodate comfortably an average family, (b) structurally sound against decay and leakage, particularly in tropical climates, and (c) sufficiently attractive to instill in the owner a sense of pride and desire to maintain the structure in good condition.

It is the principal object of the invention, therefore, to provide a building structure and methods and apparatus for the construction thereof which enable the construction of an inexpensive yet attractive and fully functional structure, which structure may be utilized as a low-cost family dwelling unit, a resort dwelling or the like.

SUMMARY OF THE INVENTION The foregoing principal object as well as others not enumerated are accomplished by a concrete building structure according to the invention which may include a base slab for defining a floor and foundation, a monolithic divider slab for defining an outside wall and a plurality of interior walls, the divider slab being secured to the base slab, a concrete roof means and means for rigidly securing the roof means to the monolithic divider slab.

The foregoing concrete building structure according to the invention may be constructed according to the method of the invention, the steps of which may include pouring a concrete base slab on the site of the building to define a foundation and floor and allowing the base slab to cure, erecting forms on the base slab to provide an opening for receiving concrete to define a monolithic divider slab, filling the opening with concrete to define the monolithic divider slab, curing the concrete of the monolithic divider slab, removing the forms, positioning a roof section on the monolithic divider slab, and securing the roof to the monolithic divider slab.

The invention also contemplates a novel form apparatus for enabling the construction of the above-described divider slab as a monolithic slab.

Finally, the invention contemplates a water-tight joint for sealing the interface between first and second concrete slabs which may include a flange on one end of each of the first and second slabs, each flange having one surface normal to the basic plane of the slabs and a surface extending obliquely to the basic plane of the slabs, the flanges cooperating to define a mating joint having a keystone cross-sectional configuration, and a resilient means extending over the flanges and in resilient frictional engagement with each of the surfaces extending to the basic plane of the slabs.

BRIEF DESCRIPTION OF THE DRAWINGS A more complete understanding of the present invention may be had from the following detailed description, particularly when considered in the light of the accompanying drawings wherein:

FIG. I is a floor plan of a building according to the inventron;

FIG. 2 is an elevational view of the building of FIG. I;

FIG. 3 is a plan view of an arrangement of forms for use in the pouring of a monolithic divider slab in constructing the building shown in FIG. I;

FIG. 4 is an elevational view similar to FIG. 2 but of the form arrangement shown in FIG. 3;

FIG. 5 is a view similar to FIG. 3 but showing the forms in partially folded positions to facilitate their removal after the completion of the pouring of a monolithic divider wall shown in FIG. 1;

FIG. 6 is detailed view of corner locking structure for securing fonn sections of FIGS. 4 and 5;

FIG. 7 is a detailed view of tongue and key locking structure for securing the form sections of FIGS. 4 and 5;

FIG. 8 is a partial perspective view of a typical corner form structure;

FIG. 9 is an exploded perspective view of the concrete building of the invention; and

FIG. 10 is a partial cross-sectional view through the plane I010 of FIG. 9.

DETAILED DESCRIPTION Referring to FIGS. I and 2, a building structure according to the invention is designated generally by reference numeral I0. Broadly, building 10 comprises a base slab 12, a monolithic divider section 14 and a roof 16.

The base slab I2 is a monolithic slab which serves as both foundation and floor for building 10. The slab is formed of concrete approximately 6 to 8 inches thick and provided with suitable reinforcing rods.

The monolithic divider section 14 is also a monolithic concrete structure, i.e. a structure formed by a single pour of concrete into a totally communicating form opening. Divider section 14 is structurally secured to base slab 12 by common reinforcing rods (FIG. 9) which are prepositioned in the base slab and which extend into the divider slab.

The roof l6 for building 10 comprises two

pre-cast concrete sections

17 and 18 which are secured to divider slab 14 by bolts 20 (FIG. 9), as is discussed below, and sealed at their interface by a novel sealing joint 22 the details of which are discussed below.

Considering the lay-out shown in FIG. 1, monolithic divider slab I4 can be seen to divide the area above base slab I2 into a terrace area 24, a living room-dining room area 25, a bedroom area 26, a kitchen area 27 and a bathroom area 28. Bedroom area 26 is divided into three

individual bedrooms

30, 31 and 32 by the provision of

closet sections

34 and 35.

Monolithic divider slab 14 includes an outside wall portion 38 which defines the outer perimeter of building 10 and a plurality of interior wall portions 40-43 which separate the bedroom 30 from the living-dining room area 25, the bedroom 32 from the bathroom area 28, the bathroom area 28 from the kitchen area 27, and the kitchen area 27 from the living-dining room area 25, respectively.

The outside wall portion is provided with a plurality of suitable window openings 45 which may be closed by glass windows of well known construction or by windows of the slotted or shutter type as are ofien utilized in tropical climates.

An opening is provided between the terrace area 24 and the living-dining room area 25 in which is mounted a door 47. Similarly, a door 48 is mounted in an opening in outer wall 38 to provide access between kitchen area 27 and the outside of building I0.

Interior doors

50, 51, 52 and 53, respectively, are provided to establish privacy for

bedrooms

30, 31 and 32 and for bathroom area 28.

As noted above,

bedrooms

30, 31 and 32 are separated by

closet sections

34 and 35. In this regard,

closet sections

34 and 35 do not form part of the monolithic divider slab I4 but rather are preconstructed closet sections of a type which are generally available on the market or which may be constructed on site. Each section may be secured to the inner surfaces of outside wall 38 by suitable stud bolts 55 which may be mounted in divider slab 14 during the pouring thereof. In this regard, it is clear that either or both of

closet sections

34 and 35 can be omitted to make the building structure a onebedroom or two-bedroom structure.

Electrical and plumbing services are provided by positioning,prior to the pouring of concrete, electrical conduit means and plumbing pipe lines within the forms for forming the monolithic divider slab. The conduits and pipe lines are retained in proper position by securing their ends to suitable openings in the concrete forms, which openings are provided for that purpose.

Thus, building comprises a structure having three basic elements, i.e. base slab, monolithic divider slab and roof. Because of the fact that the divider slab is monolithic, the structure is expedient to construct and thus relatively inexpensive.

Considering therefore the manner of constructing building 10, suitable forms (not shown) are erected on the proposed building site to accommodate the pouring of base slab 12. As is evident from FIG. 9, the forms for the base slab of building 10 define a rectangular opening and may be of suitable depth, e.g. six to eight inches, as may be appropriate for the site conditions.

In order to facilitate rapid construction, a quick drying cement may be utilized for not only the base 12, but also for the monolithic divider slab 14 and

roof sections

17 and 18. An acceptable cement for use in constructing buildings according to the invention is High Early as manufactured by the Portland Cement Co.

With the forms for base slab 12 properly positioned, the concrete therefor is poured and allowed to cure as required. Additionally, a plurality of reinforcing rods 57 are positioned so as to be set at their bottoms within base slab l2 and to extend upwardly from base 12 to ultimately be received within monolithic divider slab 14. Thereafter, the base slab forms are removed, for example to a next adjacent construction site for use in pouring another base slab.

After base 12 has been poured and allowed to cure, the forms for constructing monolithic divider slab 14 are positioned over base slab 12 in preparation for the pouring of the divider slab. As best may be seen in FIGS. 3, 4 and 5, the forms which are utilized for pouring monolithic divider slab 14 include a perimeter form members 60 and four interior form members, namely a living-dining room area form member 62, a bedroom area form member 64, a bathroom area form member 66 and a kitchen area form member 68. Thus, form

members

60, 62, 64, 66 and 68, when positioned and secured as shown in FIG. 3, cooperate with base slabe 12 to define a single opening into which concrete can be poured to form monolithic divider slab 14.

Considering the construction of the fonns in greater detail, perimeter form member 60 is best seen in FlG. 5 to comprise a first perimeter section 70, a second perimeter section 71 and a third perimeter section 72.

Perimeter sections

70 and 71 and 71 and 72 are pivotally connected by hinge means 73 and 74, mating sections of which hinges are secured such as by welding on adjacent edges of the perimeter form sections. The hinges may be of conventional construction such as those shown in FIG. 8, however, they are mounted on the outer surface of

form sections

70, 71 and 72 so as to present a smooth surface on the concrete engaging side of the forms. Thus each of the form sections comprises a plurality of sheets which may be of a suitable material such as steelv The sheets are positioned and secured to define the outer surface configuration of building 10. Additionally, each sheet may be provided with one or more stifl'eners, e. g. the angle iron stifieners 75 on form section 71 as shown in FIG. 4. The edges of

form sections

70 and 72 which are furthest removed from the pivoted edges are provided with locking means to secure the two form sections together to define the complete perimeter form 60. Locking means which are considered to be fully satisfactory are shown in FIG. 6 and comprise slotted

straps

77 and 78 which may be rigidly secured such as by welding to form

sections

70 and 72, respectively. Each of

straps

77 and 78 is provided with a slot, through which slots extend

bolts

80 and 81. The base of bolt 80 is rigidly secured to the outer surface of form section 72 by welding. Similarly, the base of bolt 81 is secured to the outer surface of form section 70 by welding. When the edges of

form sections

70 and 72 are juxtaposed, the threaded portion of bolt extends through the slot in strap 77 and the threaded portion of bolt 81 extends through the slot in strap 78. Washers and nuts are then positioned on the

bolts

80 and 81, and the nuts are tightened against the surfaces of

straps

77 and 78 until the

form sections

70 and 72 are rigidly secured in concrete supporting position. Thus, perimeter form 60 can be fully assembled by positioning form section 70, positioning form section 71 such as to engage hinges 73, positioning form section 72 such as to engage hinges 74, pivoting

form sections

70, 71 and 72 together until

bolts

80 and 81 extend through the slots in

straps

77 and 78, and thereafter rigidly securing the assembly by tightening the nuts on

bolts

80 and 81.

Interior forms 62, 64, 66 and 68 are similar to perimeter form 60 with the exceptions that each includes three or more form sections pivoted together to facilitate assembly and dis assembly, each is constructed with the hinges and stifl'eners on the inner surfaces so as to present an outwardly facing smooth surface for satisfactorily forming the concrete, and each utilizes tongue and wedge securing devices rather than the strap and bolt securing devices used for the perimeter form 60.

Referring to FIGS. 3, 5 and 7, therefore, living-dining room area form 62 can be seen to comprise five

form sections

83, 84, 85, 86 and 87.

Form sections

83 and 84 are pivotally connected by hinges 90,

form sections

84 and 85 are pivotally connected by hinges 91,

form sections

85 and 86 are pivotally connected by hinges 92, and

form sections

86 and 87 are pivotally connected by hinges 93.

The pivoted joints for adjacent form sections are identical in construction and one such typical construction is shown in FIG. 8. More specifically, FIG. 8 shows a partial perspective view of the edge between living-dining

room form sections

85 and 86, which sections are ivotally connected by hinges 92. Each hinge 92 comprises an upper leaf 95 and a lower leaf 96 pivotally connected by a pintle 98. The hinge leaves 95 and 96 are secured to form

sections

85 and 86 respectively by welding or like securing methods generally known in the art. Additionally, the

adjacent fonn sections

85 and 86 are provided with angle stiffeners 99, 100, which stiffeners are spaced vertically to permit unobstructed pivoting of the form sections.

Bedroom area form 64 includes first, second, third, fourth and fifth bedroom form sections 101 through 105 respectively. The form sections are pivotally connected, in the manner described above with respect to form

sections

85 and 86, by hinges 108-111. Similarly, bathroom area form 66 comprises first, second and third

bathroom form sections

113, 114 and 115 which are pivotally connected by

hinges

118 and 119. Additionally, kitchen area form 68 comprises first, second and third

kitchen form sections

121, 122 and 123, pivotally connected by

hinges

126 and 127.

As was noted above, the

interior forms

62, 64, 66 and 68 are interconnected by tongue and wedge type securing means. Thus, fifth living room form section 87 is secured to first bedroom form section 101 by a plurality of spaced tongue and wedge securing means 130. Similarly, first and third

bathroom form sections

113 and 115 are secured to fifth bedroom form section 105 by a plurality of spaced tongue and wedge securing means 132 and 133 respectively. Fifth bedroom form sec tion 105 is also secured to second kitchen form section 122 by tongue and wedge securing means 135.

In addition to being secured to fifth bedroom form section 105, second kitchen form section 122 is also secured to first living-dining room form section 83 by vertically spaced tongue and wedge securing means 137. Finally, first and third

kitchen form sections

121 and 123 are secured to perimeter form sec tion 71 by a plurality of vertically spaced tongue and wedge securing means 139 and 140, respectively.

Although the specific relationship of the elements may vary from joint to joint, each of the tongue and wedge securing means utilized for securing two form sections according to the invention includes a slotted tongue on one form section which is received through a suitable opening in the other form section, and a wedge which can be driven into the slot in the tongue to draw the sections tightly together and to maintain them in rigidly secured relationship.

A typical tongue and wedge securing means according to the invention is tongue and wedge 135, shown in perspective in FIG. 7 which secures fifth bedroom form section 105 with second kitchen form section 122. Referring therefore to FIG. 7, tongue and wedge means I35 can be seen to include a tongue I40 wich is rigidly secured as by welding, to form section 105. Tongue 140 extends through an opening 141 in form section I22 sufficiently far to expose a slot 142 formed in tongue 140. Received through slot 142 is a wedge device I44 which is tapered such that as it is inserted through slot I42, it bears against the inner surface of slot 142 and the surface of form section 122 to draw tongue I40 through opening 14! thereby drawing form secu'on I05 tightly against form section I22.

As noted above, the

forms

60, 62, 64, 66 and 68 are positioned on base slab 12 after it has been poured and been allowed to cure. The forms may be positioned in any sequence found to be most appropriate for the construction crew. When completely positioned, however, they appear as shown in FIG. 3, i.e. they cooperate to define a single opening into which concrete is poured to form monolithic divider slab I4. Divider slab 14 is structurally secured to base slab I2 by reinforcing rods I46 (FIG. 9) which are pre-set in base slab 12 in such positions as to extend into the opening defined by

forms

60, 62, 64, 66 and 68 when assembled.

As is evident from the various Figures, openings are provided in the walls of building 10 to allow for the mounting of windows and doors. The openings are formed by positioning between the wall defining forms, box structures which preclude the entry of concrete into the opening space during pouring. The box structures may be of wood as is conventional, or they may be defined by the actual window and door sash structures. When the sash structures are utilized, the completion of the window or door installation afler pouring of concrete requires only that the window or door be mounted within the pre-set sash.

It has been found that where openings are provided in the forms to accommodate window or door spaces, it is desirable to provide additional support means adjacent the openings, e.g. drawbolts 148 (FIG. 4), in order to avoid the occurrence of deflection or buckling in the forms during pouring and setting of the concrete which might result in leakage of concrete past the opening-defining box structures.

When constructing building I0 according to the invention, the monolithic divider slab I4 is constructed by positioning and securing

forms

60, 62, 64, 66 and 68 on base slab 12 so that reinforcing rods 146 are enclosed thereby. Suitable boxes for defining window and door openings are then positioned as required and secured within the form sections. With the forms completely assembled, i.e. disposed as shown in FIG. 3, concrete is poured and thereafter allowed to cure.

Once the concrete of divider slab 14 has cured, forms 60, 62, 64, 66 and 68 may be removed for use in a next subsequent building. Removal can be accomplished easily be dis engaging all the tongue and wedge securing devices as well as the bolt and slotted strap securing devices, folding the form sections about the hinges away from the now constructed divider slab I4, and removing, eg by crane, the form sections from the site of building 10 to a storage area or a next sub sequent building site.

Referring briefly to FIG. 9, it can be seen that there are a plurality of studs extending upwardly from the upper edge of divider slab I4 as well as a plurality of studs 55 extending into bedroom area 26 from the inner surface of slab 14. As was noted above, studs 55 are bolts for securing

closet sections

34 and 35 within slab l4. Studs 20 are for securing

roof sections

17 and 18 into slab 14 after slab I4 has been poured and cured.

Thus, after slab 14 has been poured and cured, and after

forms

60, 62, 64, 66 and 68 have been removed, roof 16 may be positioned. In this regard, the sections 17 and I8 of roof I6 may be pre-cast prior to shipment to the site, or, more desirably, they may be poured at the site. It is considered to be economically desirable to construct forms for roof sections 17 and I8 on the building site adjacent the base slab position, and thereafier pouring bath the base slab and the roof sections at the same time. Roof sections I7 and 18 are simple in form, see FIG. I0, and thus are well adapted for on site construction. Referring to FIG. I0, each

roof section

17 and 18 comprises a center portion I5], 152, a

peripheral ledge

155, 156, and a flange I59, I60. Each flange I59 and 160 has one surface norms] to the basic plane of center portions 15! and 152, and a surface I6I, I62 extending obliquely to the basic plane of center portions 151 and I52. The surfaces of flanges I59 and I60 which are normal to the basic plane of center portions l5l and I52 are provided with a tongue 163 and a groove I64, respectively. Thus, when roof sections 17 and I8 are positioned on slab I4 to define roof I6, the normal surfaces of flanges 159 and I60 including tongue I63 and groove I64, are in surface to surface engagement and the flanges cooperate to define a mating joint having a keystone cross-sectional configuration. With the roof sections so positioned, the joint therebetween is sealed by providing a U-shaped resilient cover strip I65 which extends longitudinally over the flanges between ledges and 156 and around flanges I59 and I60 to engage oblique surfaces I61 and 162.

Assuming that roof sections I7 and I8 have been poured on site, they are allowed to cure and thereafter are positioned on slab I4 by suitable means such as a crane. Each of the

ledges

155 and 156 is provided with bolt holes (not shown) for receiving stud bolts 20 therethrough, which bolts can then be provided with nuts for securing the roof sections in the manner conventionally known in the art. Additionally, buil dup of water on roof sections 17 and I8 is precluded by providing suitable drain openings through ledges 155 and I56. After the two roof sections are secured, resilient sealing strip 22 is positioned over flanges I59 and 160 and the building 10 is now ready for interior finishing.

It can be seen from the foregoing that the present invention contemplates the construction of a novel building structure by the novel method of pouring a concrete base slab on a building site for defining a foundation and a floor, allowing the base slab to cure, erecting forms on the base slab to provide an opening for receiving concrete to define a monolithic-divider slab including outside wall forming portions and interior wall forming portions, filling the opening with concrete to define the monolithic divider slab to cure, removing the forms, positioning a concrete roof on the monolithic divider slab, and securing the roof to the monolithic divider slab.

It is considered to be manifest that many modifications and variations of the present invention can be made without departing from the spirit and scope thereof.

I claim:

1. Apparatus for use in constructing a concrete building having a base slab, a monolithic divider slab for defining an outside wall and a plurality of interior walls, and a concrete roof means, in said apparatus including:

form means for cooperating with said base slab to define an opening for receiving concrete to form said monolithic divider slab wherein said form means includes a plurality of pi otally secured sections for defining the outer boundary of said outside wall and a plurality of sections for defining the inner boundaries of said outside walls and the boundaries of said interior walls.

2. Apparatus according to claim I wherein concrete building includes a living and dining room area, a kitchen area, a bathroom area and a bedroom area, and wherein said forms include:

a first form member having three sections for defining the outer surfaces of said outside walls, and

four additional form members for defining the inner surfaces of said outside walls and the surfaces of said interior walls.

said living and dining room area. one of said additional form members defines the inner surface of the walls of said bedroom area, one of said additional form members defines the inner surface of the walls of said bathroom area, and one of said additional form members defines the inner surface of the walls of said kitchen area.

Claims

1. Apparatus for use in constructing a concrete building having a base slab, a monolithic divider slab for defining an outside wall and a plurality of interior walls, and a concrete roof means, in said apparatus including: form means for cooperating with said base slab to define an opening for receiving concrete to form said monolithic divider slab wherein said form means includes a plurality of pivotally secured sections for defining the outer boundary of said outside wall and a plurality of sections for defining the inner boundaries of said outside walls and the boundaries of said interior walls.

2. Apparatus according to claim 1 wherein concrete building includes a living and dining room area, a kitchen area, a bathroom area and a bedroom area, and wherein said forms include: a first form member having three sections for defining the outer surfaces of said outside walls, and four additional form members for defining the inner surfaces of said outside walls and the surfaces of said interior walls.

3. Apparatus according to claim 2 wherein said sections of said first form member are joined pivotally at adjacent edges thereof.

4. Apparatus according to claim 2 wherein each of said four additional form members include a plurality of sections pivotally secured at adjacent edges.

5. Apparatus according to claim 2 wherein one of said additional form members defines the inner surface of the walls of said living and dining room area, one of said additional form members defines the inner surface of the walls of said bedroom area, one of said additional form members defines the inner surface of the walls of said bathroom area, and one of said additional form members defines the inner surface of the walls of said kitchen area.