WO1996033324A1 - Method of manufacturing shell formed constructions - Google Patents

Method of manufacturing shell formed constructions Download PDF

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Publication number
WO1996033324A1
WO1996033324A1 PCT/SE1996/000460 SE9600460W WO9633324A1 WO 1996033324 A1 WO1996033324 A1 WO 1996033324A1 SE 9600460 W SE9600460 W SE 9600460W WO 9633324 A1 WO9633324 A1 WO 9633324A1
Authority
WO
WIPO (PCT)
Prior art keywords
membrane
sheath
space
sheaths
powder
Prior art date
Application number
PCT/SE1996/000460
Other languages
French (fr)
Inventor
Hans Gunnar Larsson
Original Assignee
H.G. Tech Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by H.G. Tech Ab filed Critical H.G. Tech Ab
Publication of WO1996033324A1 publication Critical patent/WO1996033324A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/04Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for structures of spherical, spheroid or similar shape, or for cupola structures of circular or polygonal horizontal or vertical section; Inflatable forms
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B63SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63BSHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B5/00Hulls characterised by their construction of non-metallic material
    • B63B5/14Hulls characterised by their construction of non-metallic material made predominantly of concrete, e.g. reinforced
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/167Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with permanent forms made of particular materials, e.g. layered products
    • E04B1/168Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with permanent forms made of particular materials, e.g. layered products flexible
    • E04B1/169Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with permanent forms made of particular materials, e.g. layered products flexible inflatable
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/04Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for structures of spherical, spheroid or similar shape, or for cupola structures of circular or polygonal horizontal or vertical section; Inflatable forms
    • E04G11/045Inflatable forms

Definitions

  • the present invention relates to a method of manufacturing shell-shaped constructions, preferably of concrete, such as houses, ships' hulls, etc.
  • a flexible membrane (rubber) is coated with concrete, and suitably reinforcing mesh, after which the membrane is inflated to the desired size and the concrete then allowed to solidify (SE 330435).
  • a non-flexible membrane is inflated and concrete is then applied externally by means of spraying (SE 357230).
  • a flexible or non-flexible membrane is inflated and the "balloon" is then coated internally with an insulating foam which is allowed to solidify, thus improving the rigidity of the balloon, after which concrete is sprayed on internally (EP 0357151).
  • a method constituting a solution to these problems is claimed in Swedish patent application 9303576-4.
  • This method is characterized in that two flexible sheaths or membranes are arranged, an upper sheath outside a lower sheath, with a space between them into which powder material is filled, both sheaths being attached to a support surface or to the ground, after which pressure medium such as air is blown in between the support surface/ round, or an auxiliary membrane, and a lower sheath/ membrane, so that the sheath/ membrane construction is inflated to the desired shape, after which the space between the sheaths /membranes is evacuated with the aid of a vacuum pump, thereby compacting the powder to rigidity, after which concrete, such as fibre-reinforced concrete, is sprayed onto the exterior of the upper sheath / membrane, and that when the concrete has set/ solidified the pressure medium is released and air is allowed to enter the space. It is thus possible to build normal-sized or large buildings of hemispherical shape, round
  • the present invention relates to a further development of the method for which a patent application has been applied, and entails an equivalent solution to the problems mentioned above.
  • the method according to the present invention is characterized in that two flexible sheaths are arranged, an upper sheath outside a lower sheath, with a space between them into which powder or particle-shaped material and binder are filled.
  • Both sheaths are attached to a support surface or to the ground, after which pres ⁇ sure medium such as air is blown in between the support surface /ground and the lower sheath/ membrane, so that the sheath/ membrane construc ⁇ tion is inflated to the desired shape, after which the space between the sheaths / membranes is evacuated with the aid of a vacuum pump, and the powder/ particles in this layer are allowed to set and a rigid layer is obtained where communication between its particles is retained.
  • pres ⁇ sure medium such as air is blown in between the support surface /ground and the lower sheath/ membrane
  • This method is an alternative to the method first mentioned and offers an alternative to build normal-sized or larger buildings of hermispherical or spherical shape and extensions for other house designs.
  • Figures la-lc show various stages of erection of a mould for the body of a house, a ship's hull, etc. and a template for an insulating layer such as concrete, etc. i.e. a first stage in constructing a house, a ship's hull, etc.
  • Figure Id shows concrete being sprayed on.
  • Figures 2a-2e show the alternative production of ship's hulls or the like, according to the invention.
  • Figure la reveals how two membranes, an upper membrane (4) and a lower membrane (1) are placed and anchored in a foundation (2).
  • a powder material such as sand, sawdust, porous clay pellets, etc., and binder such as cement paste, polymers or other binder, are filled into the space (3) between the membranes.
  • binder such as cement paste, polymers or other binder
  • Figure lb shows how a pressure medium such as air is blown into the space (7) below the lower membrane (1) with the aid of a pump (5), and the membranes (1, 4) with the powder between them are lifted to the desired shape, possibly under partial vacuum.
  • a positive pressure of 0.001-0.01 bar in the space (7) is sufficient, depending on the diameter of the membrane. However, the diameter should be relatively large (for constructing a house, for instance).
  • Leca pellets, i.e. pellets of expanded clay may be placed in the space, as well as binder.
  • the air is evacuated from the powder space (3), see Figure lc, and after setting a rigid layer is obtained with communication between the various particles. The layer has satisfactory rigidity and strength.
  • This rigidity prevents deformation of the parts of the mould and a firm layer is obtained.
  • An insulating layer is applied on this mould, intended to provide heat and moisture insulation, either by leaving the upper membrane (4) in place or, after removal thereof, by spraying on an insulating material such as concrete, elastomer (rubber or plastic) (4).
  • Evacuation is obtained with the aid of a vacuum pump (6). The vacuum will cause the membranes (1, 4) to be pressed towards each other, thus compressing the powder. An extremely rigid composite is thus produced, giving good stability to the entire casting mould.
  • Figure Id shows the next step in which concrete and fibre, fibre-reinforced concrete, is sprayed (at 8) against the mould (9b).
  • the air is released from the space (7) below the membrane (1) and air is allowed into the space (3) between the membranes (1, 4). Compacting is thus cancelled and the membranes can be removed for re-use while the substructure (9a) remains.
  • the upper member (4) may possibly be retained as an insulating layer.
  • Lower vacuum may possibly be used during inflation when performing the method according to the invention, in order to prevent the powder from running.
  • Concrete is sprayed on here ( Figure Id), such as concrete and fibre, or sand and cement, water and fibre separately.
  • the procedure also allows a certain modification of the shape after inflation, in that the powder material in the space (3) can be deposited in different thicknesses , or may consist of powder having different density.
  • a more elliptical shape can be achieved, for instance, by using a powder with higher density (sand and sawdust) at the centre, while the remainder may be primarily sawdust.
  • the membrane will be weighted down where the sand is and will not be blown up as high as otherwise.
  • An insulating layer may also be placed below the lower member (1).
  • Figure 2a-2b shows the production of a ship's hull in accordance with the invention.
  • Figure 2a shows an example of membrane shape.
  • Figure 2b is a section along the line A-A in Figure 2a.
  • (18) is an auxiliary membrane and (1 and 4) are membranes as above.
  • (5) is a pressure pump and (6) a vacuum pump. The procedure is in accordance with the first example.
  • Main lines (19) are secured to the outer membrane, see Figure 2c, in order to achieve the desired hull shape.
  • Pressure medium e.g. air

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ocean & Marine Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Combustion & Propulsion (AREA)
  • Electromagnetism (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
  • Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)
  • Tents Or Canopies (AREA)

Abstract

The present invention relates to a method of manufacturing shell-shaped constructions, preferably of concrete, such as houses, ships' hulls, etc. According to the invention two flexible sheaths are arranged, an upper sheath outside a lower sheath, with a space (3) between them (1, 4) into which powder or particle-shaped material and binder are filled. Both sheaths (1, 4) are attached to a support surface or to the ground (2), after which pressure medium such as air is blown in between the support surface/ground (2) and the lower sheath/membrane (1), so that the sheath/membrane construction is inflated to the desired shape, after which the space (3) between the sheaths/membranes is evacuated with the aid of a vacuum pump (6), and the powder/particles in this layer are allowed to set so that a rigid layer is obtained where communication between its particles is retained.

Description

Method of manufacturing shell formed constructions.
Technical field: The present invention relates to a method of manufacturing shell-shaped constructions, preferably of concrete, such as houses, ships' hulls, etc.
Background art:
It is already known to coat an inflated rubber membrane with concrete either before or after inflation, the membrane being removed after the concrete has set. The known technology can be divided into three groups:
1. A flexible membrane (rubber) is coated with concrete, and suitably reinforcing mesh, after which the membrane is inflated to the desired size and the concrete then allowed to solidify (SE 330435).
2. A non-flexible membrane is inflated and concrete is then applied externally by means of spraying (SE 357230).
3. A flexible or non-flexible membrane is inflated and the "balloon" is then coated internally with an insulating foam which is allowed to solidify, thus improving the rigidity of the balloon, after which concrete is sprayed on internally (EP 0357151).
The drawbacks of the above procedures are:
1. The method functions well for smallish constructions, e.g. a hemisphere with less than 5-6 m diameter. The procedure is difficult to perform satisfactorily with larger constructions due to problems of instability. Very moderate winds during the casting, for instance, may cause deformation of the "balloon" which jeopardizes the entire casting. 2. Here the problems of instability described under 1. are eliminated by the "balloon" being pumped up to a higher pressure, e.g. 0.1 bar, or about 10 times the pressure used under 1.
The drawback with high pressures is the enormous forces required to keep the balloon/ hemisphere on the ground. (One ton per square metre is required for a pressure of 0.1 bar in the hemisphere, a construction with an area of 200 m2 takes 200 ton.)
3. Here the instability problems are solved with the aid of foam and moderate pump pressure can be used. The drawback with this procedure is the complex internal reinforcing system required and the great waste of concrete which is unavoidable when spraying internally (from below).
It is also known to fill powder into a space between two pipes (membranes) and evacuate the air from this space so the powder is compacted thereby producing a more rigid body (US 3258883). There is no intimation in this publication of using the procedure for building purposes.
Summary of the invention: A method constituting a solution to these problems is claimed in Swedish patent application 9303576-4. This method is characterized in that two flexible sheaths or membranes are arranged, an upper sheath outside a lower sheath, with a space between them into which powder material is filled, both sheaths being attached to a support surface or to the ground, after which pressure medium such as air is blown in between the support surface/ round, or an auxiliary membrane, and a lower sheath/ membrane, so that the sheath/ membrane construction is inflated to the desired shape, after which the space between the sheaths /membranes is evacuated with the aid of a vacuum pump, thereby compacting the powder to rigidity, after which concrete, such as fibre-reinforced concrete, is sprayed onto the exterior of the upper sheath / membrane, and that when the concrete has set/ solidified the pressure medium is released and air is allowed to enter the space. It is thus possible to build normal-sized or large buildings of hemispherical shape, round or flattened, or shapes deviating from these, at relatively low cost.
The present invention relates to a further development of the method for which a patent application has been applied, and entails an equivalent solution to the problems mentioned above. The method according to the present invention is characterized in that two flexible sheaths are arranged, an upper sheath outside a lower sheath, with a space between them into which powder or particle-shaped material and binder are filled. Both sheaths are attached to a support surface or to the ground, after which pres¬ sure medium such as air is blown in between the support surface /ground and the lower sheath/ membrane, so that the sheath/ membrane construc¬ tion is inflated to the desired shape, after which the space between the sheaths / membranes is evacuated with the aid of a vacuum pump, and the powder/ particles in this layer are allowed to set and a rigid layer is obtained where communication between its particles is retained.
This method is an alternative to the method first mentioned and offers an alternative to build normal-sized or larger buildings of hermispherical or spherical shape and extensions for other house designs.
Brief description of the drawings:
The invention is illustrated in more detail in the accompany drawings in which Figures la-lc show various stages of erection of a mould for the body of a house, a ship's hull, etc. and a template for an insulating layer such as concrete, etc. i.e. a first stage in constructing a house, a ship's hull, etc. Figure Id shows concrete being sprayed on. Figures 2a-2e show the alternative production of ship's hulls or the like, according to the invention.
Preferred embodiment:
Figure la reveals how two membranes, an upper membrane (4) and a lower membrane (1) are placed and anchored in a foundation (2). A powder material such as sand, sawdust, porous clay pellets, etc., and binder such as cement paste, polymers or other binder, are filled into the space (3) between the membranes. However, only in such quantity that the skeleton structure of the layer is obtained, i.e. communication between the particles remains, unlike the previously claimed method. The membranes (1, 4) are attached to the foundation (2) or a support surface.
Figure lb shows how a pressure medium such as air is blown into the space (7) below the lower membrane (1) with the aid of a pump (5), and the membranes (1, 4) with the powder between them are lifted to the desired shape, possibly under partial vacuum. A positive pressure of 0.001-0.01 bar in the space (7) is sufficient, depending on the diameter of the membrane. However, the diameter should be relatively large (for constructing a house, for instance). Leca pellets, i.e. pellets of expanded clay, may be placed in the space, as well as binder. When the desired shape has been obtained, the air is evacuated from the powder space (3), see Figure lc, and after setting a rigid layer is obtained with communication between the various particles. The layer has satisfactory rigidity and strength. This rigidity prevents deformation of the parts of the mould and a firm layer is obtained. An insulating layer is applied on this mould, intended to provide heat and moisture insulation, either by leaving the upper membrane (4) in place or, after removal thereof, by spraying on an insulating material such as concrete, elastomer (rubber or plastic) (4). Evacuation is obtained with the aid of a vacuum pump (6). The vacuum will cause the membranes (1, 4) to be pressed towards each other, thus compressing the powder. An extremely rigid composite is thus produced, giving good stability to the entire casting mould.
Figure Id shows the next step in which concrete and fibre, fibre-reinforced concrete, is sprayed (at 8) against the mould (9b). When the concrete has set the air is released from the space (7) below the membrane (1) and air is allowed into the space (3) between the membranes (1, 4). Compacting is thus cancelled and the membranes can be removed for re-use while the substructure (9a) remains. The upper member (4) may possibly be retained as an insulating layer.
Lower vacuum may possibly be used during inflation when performing the method according to the invention, in order to prevent the powder from running. Concrete is sprayed on here (Figure Id), such as concrete and fibre, or sand and cement, water and fibre separately.
The procedure also allows a certain modification of the shape after inflation, in that the powder material in the space (3) can be deposited in different thicknesses , or may consist of powder having different density. A more elliptical shape can be achieved, for instance, by using a powder with higher density (sand and sawdust) at the centre, while the remainder may be primarily sawdust. The membrane will be weighted down where the sand is and will not be blown up as high as otherwise. An insulating layer may also be placed below the lower member (1).
Figure 2a-2b shows the production of a ship's hull in accordance with the invention. Figure 2a shows an example of membrane shape. Figure 2b is a section along the line A-A in Figure 2a. (18) is an auxiliary membrane and (1 and 4) are membranes as above. (5) is a pressure pump and (6) a vacuum pump. The procedure is in accordance with the first example. Main lines (19) are secured to the outer membrane, see Figure 2c, in order to achieve the desired hull shape. Pressure medium (e.g. air) is pumped by a pressure pump (5) into a space between the auxiliary membrane (18) and the inner membrane (1), and the sheath/ membrane body is blown down into a space for the purpose below the construction. The space (3) is then evacuated and the powder therein is compacted to rigidity (Figure 2d). When the hardened mould has been obtained as above, the auxiliary membrane is removed (Figure 2e), and an insulating layer may be sprayed on (at 21) to produce a ship's hull.
The method according to the invention can be varied in many ways within the scope of the following claims.
'.BAD ORIGINAL g

Claims

1. A method of manufacturing shell-shaped constructions, preferably of concrete, such as houses, ships' hulls, etc., characterized in that two flexible sheaths are arranged, an upper sheath outside a lower sheath, with a space (3) between them (1, 4) into which powder or particle-shaped material and binder are filled, both sheaths (1, 4) being attached to a support surface or to the ground (2), after which pressure medium such as air is blown in between the support surface/ ground (2) and the lower sheath/ membrane (1), so that the sheath /membrane construction is inflated to the desired shape (9), after which the space (3) between the sheaths /membranes is evacuated with the aid of a vacuum pump (6), and the powder/ particles in this layer are allowed to set and a rigid layer is obtained where communication between its particles is retained.
2. A method as claimed in claim 1, characterized in that a heat and /or moisture insulating layer is arranged on the rigid lay, either by leaving the upper membrane in place or, after removal thereof, by applying insulating material.
3. A method as claimed in claim 1, characterized in that before blowing in of the pressure medium has been completed, cables, wires or bands are placed over the upper membrane (4) so that the final product acquires a shape deviating from hemispherical or partially spherical shape.
4. A method as claimed in claim 1, characterized in that pressure medium/ air is blown in between a support surface or an auxiliary member (18) and one of the sheaths (1) placed beneath the support surface /auxiliary member (18), so that the sheath/ membrane construction is blown downwardly to the desired shape in a space provided for the purpose.
5. A method as claimed in one or more of the preceding claims, characterized in that the powder in the space (3) is poured in with different density and /or different thickness at different parts of the surface so that the final product acquires a shape deviating from hemispherical or partially spherical shape.
6. A method as claimed in one or more of claims 1-5, characterized in that when the body has been fully cast, insulating material is placed thereon and then covered by plastic such as shrink plastic, after which concrete, such as fibre-reinforced concrete, is sprayed onto the plastic in an outer layer
PCT/SE1996/000460 1995-04-20 1996-04-10 Method of manufacturing shell formed constructions WO1996033324A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE9501443A SE504224C2 (en) 1995-04-20 1995-04-20 Ways to produce a shell-shaped structure with an inflatable mold
SE9501443-7 1995-04-20

Publications (1)

Publication Number Publication Date
WO1996033324A1 true WO1996033324A1 (en) 1996-10-24

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WO (1) WO1996033324A1 (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10340678A1 (en) * 2003-09-04 2005-04-28 Robert Off Method for producing the wall of a building
WO2007061299A1 (en) * 2005-06-29 2007-05-31 Van Hove Robert Marius Willibr Method for manufacturing a building construction of curable material, building construction and kit of parts therefor
ES2383971A1 (en) * 2011-01-24 2012-06-28 Van Den Bos Tore Trijnko Obbe System of construction of ducts and other hollow structures. (Machine-translation by Google Translate, not legally binding)
DE102013016659A1 (en) 2013-10-09 2015-04-09 Hochschule Anhalt Process for the production of a form-active structure and a structural support structure
NL2016558B1 (en) * 2016-04-06 2017-10-17 Josephus Maria Van Bree Johannes Supporting element, in particular a self-supporting supporting element, as well as a method for manufacturing the supporting element
CN114901547A (en) * 2019-12-30 2022-08-12 V·N·阿尼西莫夫 Method for manufacturing a hull of a floating vessel

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3462521A (en) * 1966-12-12 1969-08-19 Binishells Spa Method for erecting structures
SE357230B (en) * 1968-03-07 1973-06-18 H Heifetz
FR2268924A1 (en) * 1974-04-26 1975-11-21 Joint Francais Inflatable formwork for domed concrete structure - cover over sheet clamped over plinth by strap and inflatable ring
GB1590388A (en) * 1976-10-07 1981-06-03 Binishells Spa Method for erecting substantially dome-like building structures

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3462521A (en) * 1966-12-12 1969-08-19 Binishells Spa Method for erecting structures
SE357230B (en) * 1968-03-07 1973-06-18 H Heifetz
FR2268924A1 (en) * 1974-04-26 1975-11-21 Joint Francais Inflatable formwork for domed concrete structure - cover over sheet clamped over plinth by strap and inflatable ring
GB1590388A (en) * 1976-10-07 1981-06-03 Binishells Spa Method for erecting substantially dome-like building structures

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10340678A1 (en) * 2003-09-04 2005-04-28 Robert Off Method for producing the wall of a building
WO2007061299A1 (en) * 2005-06-29 2007-05-31 Van Hove Robert Marius Willibr Method for manufacturing a building construction of curable material, building construction and kit of parts therefor
ES2383971A1 (en) * 2011-01-24 2012-06-28 Van Den Bos Tore Trijnko Obbe System of construction of ducts and other hollow structures. (Machine-translation by Google Translate, not legally binding)
DE102013016659A1 (en) 2013-10-09 2015-04-09 Hochschule Anhalt Process for the production of a form-active structure and a structural support structure
NL2016558B1 (en) * 2016-04-06 2017-10-17 Josephus Maria Van Bree Johannes Supporting element, in particular a self-supporting supporting element, as well as a method for manufacturing the supporting element
CN114901547A (en) * 2019-12-30 2022-08-12 V·N·阿尼西莫夫 Method for manufacturing a hull of a floating vessel

Also Published As

Publication number Publication date
SE504224C2 (en) 1996-12-09
SE9501443D0 (en) 1995-04-20
SE9501443L (en) 1996-10-21

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