Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/0029—Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts
  • B28B7/0035—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding
  • B28B7/0044—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding the sidewalls of the mould being only tilted away from the sidewalls of the moulded article, e.g. moulds with hingedly mounted sidewalls
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/0029—Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts
  • B28B7/0035—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding
  • B28B7/0041—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding the sidewalls of the mould being moved only parallelly away from the sidewalls of the moulded article
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
  • B28B7/007—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating natural effets, e.g. wood or stone
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
  • B28B7/0079—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with surfaces for moulding interlocking means, e.g. grooves and ribs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/24—Unitary mould structures with a plurality of moulding spaces, e.g. moulds divided into multiple moulding spaces by integratable partitions, mould part structures providing a number of moulding spaces in mutual co-operation
  • B28B7/241—Detachable assemblies of mould parts providing only in mutual co-operation a number of complete moulding spaces
  • B28B7/243—Detachable assemblies of mould parts providing only in mutual co-operation a number of complete moulding spaces for making plates, panels or similar sheet- or disc-shaped objects
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article

Definitions

• the present disclosure relates generally to devices for forming structures, and more particularly, but not necessarily entirely, to devices for forming precast concrete structures.
• the present disclosure also relates generally to structural columns and/or walls, and more particularly, but not necessarily entirely, to pre-cast concrete structures and mechanisms for attaching the structures to footings or other such supports.
• Precast concrete structures have been used in the building construction industry for many years. Precast concrete structures may include steel reinforced panels for use in constructing fences, walls, sound barriers and the like. Precast concrete structures may also include columns for supporting panels or overhead items. High quality precast concrete structures may be formed efficiently since they may be constructed in a factory with specialized equipment, strict quality standards and controlled conditions not subject to rain, hot or cold temperatures, or buiLlder errors. Moreover, labor savings may be accomplished since precast structures may be formed more efficiently in a factory than constructing a form on site to manufacture the structures in place. Use of precast concrete structures may also reduce construction delays associated with rain or inclement weather since concrete may not be properly poured on site in inclement weather.
• precast concrete panels may have various different patterns such as stone or brick, for example. Such precast concrete panels may be easier to construct than stone or brick walls.
• precast »'" ' ii -" C fc ⁇ ic:re '; ⁇ e'' 1 pk'he'is"ffiy”be durable and provide advantages in tha_t cracking may be reduced as compared to walls formed with grouted natural stone or brick, and no mortar joints are created with precast concrete panels to allow water to seep into the wall .
• FIG. 1 is a perspective break-away view of one embodiment of structures made in accordance with the principles of the 5 present disclosure
• FIG. 2 is a perspective view of one embodiment of an apparatus for making the structures of FIG. 1 in accordance with the principles off the present disclosure
• FIG. 3 is a top view of the apparatus of FIG. 2;
• FIG. 4 is an exploded top view of adjacent partitions of the apparatus of FIG. 2;
• FIG. 5 is an end view of the apparatus of FIG. 2;
• FIG. 6 is a side view of the apparatus of FIG. 2;
• FIG. 7 is a side view of a partition as shown in FIGS. 5 3 and 4;
• FIG. 8 is a cross-sectional view of the partition of FIG. 7 taken along line A-A.
• FIG. 9 is a side view of a panel useful with the partition of FIG. 8; 0 FIG. 10 is a side view of an upper member of the panel of FIG. 9;
• FIG. 11 is a side view of a lower member of the panel of FIG. 9;
• FIG. 12 is a side view of a first side member of the 5 panel of FIG. 9;
• FIG. 13 is a side view of a second side member of the panel of FIG. 9;
• FIG. 14 is an end. view of a support on the apparatus of FIG. 2;
• FIG. 15 is a perspective break-away view of another embodiment of structures made in accordance with the principles of the present disclosure;
• FIG. 16 is a break away top view of an embodiment of structures in accordance with the principles of the present 5 disclosure; cross sectional view of a structure of
• FIG. 16 taken along line A-A;
• FIG. 18 is a break away top view of an alternative embodiment of structures in accordance with the principles of the present disclosi ⁇ re;
• FIG. 19 is a break away top view of an additional alternative embodiment structure in accordance with the principles of the prresent disclosure.
• FIG. 20 is a top view of another alternative embodiment structure in accordance with the principles of the present disclosure.
• FIG. 21 is a top view of a further alternative embodiment structure in accordance with the principles of the present disclosure
• FIG. 22 is a side view of one embodiment of a member embedded in a footing
• FIG. 23 is a side view of one embodiment of a member attached to a footing
• FIG. 24 is a s ⁇ de view of an alternative embodiment of a member attached to a footing
• FIG. 25 is a side view of one embodiment of a structixre attached to a footing
• FIG. 26 is a side view of an alternative embodiment structure attached to a footing
• FIG. 27 is a side view of an additional alternative embodiment structure attached to a footing.
• crete shall be construed broadly to include conglomerate construction materials, including construct ⁇ on materials formed of aggregate and cementitious materials, as well as any other known material that may be placed in a fluid or semi-fluid form and harclened or solidified, including filler materials joined together with a bonding agent or iresin.
• substantially rigid shall be construed broadly to include members that may not: be completely rigid, but may have sufficient rigidity to support a structure at the time the structure is installed.
• the phrase "surface treatment" shaL.1 be construed broadly to include any variety of textures or designs or features that may be placed on the exterior of a concrete structure.
• ⁇ '1 j! " •"'" yi :i; 6&id ⁇ SSIlft' 1 ' 1
• attached shall be construed broadly to include situations in which members are secured or joined together, including situations in which one member is embedded into another member, and situations in which intervening membeitrs are used to join one member to another member such that the two members need not physically contact each other.
• Each structure 10 may be formed of reinforced concrete, and may include a panel port-Lon 12, for forming a wall, such as a fence or sound barrier, for example.
• the structure 10 may also form part of a retaining wall, building, or any other such construct.
• the panel portion 12 may include a surface treatment 13 or decorative pattern, such as stone or brick, for example, formed on an exterior surface.
• the structure 10 may also include a column portion 14 for supporting the panel portion 12.
• the column portion 14 may have an increased lateral dimension as compared to the panel portion to allow increased vertical and lateral support of loads as the loads are transferred to a footing, floor, or other support member.
• the column portion 14 may also include a slot 15 for receiving a panel portion 12 of an adjacent structure 10. Accordingly, a plurality of structures 10 may be joined together to form a wall of a desired length and configuration.
• the structure 10 may be supported on footings 16.
• the footings 16 may be formed in any manner known to those skilled in the art, such as cast in place reinforced concrete.
• A- rigid member 17, shown in dashed lines in FIG. 1, such as an "I" beam, post, or rod, for example, may be fixed into the ffooting 16.
• some embodiments of the present disclosure may include a rigid member 17 embedded into the footing 16, or other embodiments may include rigid members 16 by welding, bolts, or any other suitable method known to those skilled in the art.
• the rigid member 17 may be received in the slot 15 of the column portions 14 to support the structure 10 in an upright position. Some embodiments may also include the placement of concrete within the slot 15 of the column portions 14 to provide additional support to the structure 10.
• FIG. 10 may include plates (not shown) attached to the footings 16 and the column portions 14 such that the plates may be attached together to support the structure 10 in an upright position. It will be understood that the plates may be imbedded into the footings 16 and column portions 14, or the plates may be attachied to the footings 16 and column portions 14 using any other attachment method known in the art. Moreover, the plates on the footings 16 and column portions 14 may be attached together by welding, bolting, or any other attachment mechanism known to those skilled in the art. Similarly, any other suitable installation technique or device may be used to install the structure 10 within the scope of the prresent disclosure .
• the structure 10 of the present disclosure may not include the column portions 14.
• Other embodiments of the structure ILO may not include the slots 15 within the column portions 14 _
• Yet other embodiments of the structure 10 may include column portions 14 having upward extending openings in an interior of the column portions 14, such that the openings may be surrounded by concrete .
• the structure 10 may be formed in various different cross-sectional shapes . Accordingly it will be understood that the structure 10 may have various different configurations within the scope of the present disclosure, and various different attachment mechanisms and methocls may be utilized to install the structure 10. * " ' " Referring now to FIG.
• FIG. 2 a perspective view is slnown of one embodiment of an apparatus, indicated generally at 20, for forming structures 10 in accordance with the principles of the present disclosure.
• the apparatus 20 may include a frrame 22 and a base 23 for supporting a plurality of partitions 24.
• the frame 22 may be formed of an arrangement of columns , beams and/or braces configured to support the partitions 24 .and the structures 10 formed by the apparatus 20.
• the base 23 may form a foundation for the apparatus 20 such that the apparatus 20 may be placed on the ground or any variety of floor surfaces .
• the partitions 24 may define one or more cavities 26 for receiving concrete to form the structures 10.
• One embodiment of the partitions 24 may be configured to form a cavity 26 having a first portion 28 configured for forming the panel portion 12 of the structure 10, and a second portion 30 configured for forming the column portion 14 of the structure 10.
• the first portion 28 of the cavity 26 may be contiguous with the second portion 30 of the cavity 26 such that the structure 10 may be formed with the panel portion 12 and the column portion 14 integrally joined as a single piece member.
• the second portion 30 of the cavity 26 for forming the column portion 14 of the structure 10 may be formed having a wider dimension than the first portion 28 of the canity 26 for forming the panel portion 12 of the structuzre 10.
• a column portion 14 of the structure 10 may be formed to withstand increased loads transferred from the panel portion 12 to the footing 16 or other ' such support member.
• the partitions 24 may fc>e arranged such that the second portions 30 of the cavities 26 for forming the column portion 14 of the structures 10 may be arranged on opposing ends of the apparatus 20 on adjacent partitions 24.
• the apparatus may be configured to form six structures L 0 at a time, and three of the column portions 14 of the structures ⁇ c> I!" T . ⁇ a p 1 I".;; ill c- .• • ⁇ "- ⁇ > qi f ii n cii
• Hd may "" ⁇ e formed or ⁇ J ofie end of the apparatus 20, and the other three column portions 14 may be formed at the opposite end of the apparatus 20, with each adjacent structure 10 being formed with the column portions 14 on opposite ends of the apparatus 20. It will be understood, however, that the apparatus 20 may be configured, to form various different quantitl es of structures 10 at a time, and that the partitions 24 ⁇ nay be configured in various different arrangements.
• One or more ribs 31 may be positioned in the second portion 30 of the cavity 26 for forming the slot 15 in the column portion. 14 of the structure.
• the ribs 31 may be sized and shaped corresponding to the desired size and shape of the slot 15 in the column portion 14 of the structure.
• Th-e ribs 31 may be positioned at any desired location such th.a.t the concrete structures 10 may be formed as desired.
• the rib 31 may be placed to form the slot 15 in the end of the concrete structures 10, such that the panel portion 12 of a concrete structure 10 may be received in the slot 15 of an adjacent concrete structure 10 to form a substantially straight barrier.
• the rib 31 may be placed in a side of the end off the partition 24 such that the slot 15 may extend substantially perpendicular to the panel portion 12 to allow adjacent concrete structures 10 to form a corneir. It will be understood that the ribs 31 may be positioned at any desired angle or location within the scope of the present disclosure. Moreover, some embodiments of the apparatus 20 may include one or more ribs 31 positioned in other pa.rts of the cavity 26 to form slots in the panel portion 12 of the structure 10, or to form openings within an interior of the column portion 14.
• One embodiment of the present disclosure may includecie ribs 31 that may be removably attached using bolts, indicated by dashed lines at 29, such that the ribs 31 may be removed and repositioned as desired. It will be understood that other embodiments of the present disclosure may include other" types of attachment mechanisms for the ribs 31, and some embodiments "M ⁇ r ⁇ sure may include ribs that may b e f ixed in place . Otl ⁇ er embodiments may not include any rilfos such that the structures may be formed without slots 15 .
• the partitions 24 may be positioned in a side 3oy side arrangement and at least some of the partitions 24 may be configured to be movable with respect to the frame 22 to facilitate placing reinforcing steel into the cavity/ 26 as well as to facilitate removing the structure 10 after the concrete has hardened .
• FIG . 4 shows an exploded top -view of adj acent partitions 24 . It will be appreciated ttnat the partitions 24 may be separated such that reinforcing st eel may be placed between the partitions 24 .
• the partitions 24 may be j oined together such that end panels 46 on a «dj acent partitions 24 come into contact with each other .
• the cavity 26 may thereby be def ined by the partit icons for receiving concrete for forming the structure 10 .
• the partitions 24 may be separa. ted for removing the .structure 10 .
• One embodiment of the apparatus 20 may include wheels 32 for supporting the partition s 24 on the frame 22 and allowing the partitions 24 to be easily moved .
• the frame 22 may include a support 34 for receiving the wheels 32 .
• the support 34 may extend, laterally to provide a space to allLow the partitions 24 to be moved apart from each other .
• An overhang portion 36 of the support 34 may be detachable such tlhat the width of the apparatus 20 may be reduced to fac ilitate transporting tlie apparatus 20 .
• Any attachment mechanis m known in the art such as bolts , pins , or clamps , for examp le , may be used to attach the overhang portion 36 to the remai -nder of the support 34 .
• the apparatus may be szLzed to fit on a trail er, rail car or other such transporting device to be transported on rails or highways .
• the apparatus 20 may include a one piece support 34 that may not be configured to be deta ched or otherwise retracted to a compact conf iguration .
• the support 34 may include tracks 38 for assisting in maintaining the wheels 32 in positi_on.
• An end view of the support 34 showing one embodiment of the tracks 38 is shown in FIG. 14.
• the tracks 38 may form ridges for guiding the wheels 32 along a specified path on the support 34.
• the tracks 38 may be formed in any suitable configuration and manner, and ttuat some embodiments of: the present disclosure may not include tracks .
• the wheels 32 may be joined to the partitions 24 through arms 40.
• Adjacent arms 40 may have different lengthts, such as a short a-trm 42 and a long arm 44, such that adjacent partitions 24 may be configured to abut each other without interference from the wheels 32.
• the arms 40 having different lengths allow the wheels 32 to extend at different locations along the support 34 without contacting each other to thereby allow the partitions 24 to be positioned in an etbutting arrangement.
• One embodiment of the apparatus 20 may include one or more partitions 24 that may be fixed in place.
• an end partition 25 on an external side of the apparatus 20 may be attached to the frame 22 so as to be stationary-
• Other embodiments off the apparatus 20 may include partitions 24 that may all be moveable.
• the apparatus 20 may include an end wall or door 48 for enclosing- an end of the partitions 24. It will be understood that a door 48 may be positioned on oppos__ng ends of the apparatus 20. Alternatively, it will be uncLerstood that the door 48 may be positioned on a single end of the apparatus 20.
• the door 48 may be supported on door Vi/tieels 50 on opposing sides such that the door 48 may be capable of moving in a longitudinal direction of the apparatus from the partitions 24 in a direction substantially perpendicular to the direction of movement of the partitions 24. iVs shown most clearly in FIG.
• one embodiment of the present disclosure may provide a door 48 that can be moved in a translational manner for at least a part of its movement path. In other words, every point on the door 48 may move parallel to and the same distance as every other point on the door 48.
• one or more of the partitions 24 may be configured to move in a translational manner, and the direction of movement of the partitions 2 ⁇ 4 may be substantially perpendicular to the movement of the door 48.
• a hinge 53 may also be provided for the door 48 such that when the door 48 is moved a distance away from the partitions 24 into alignment with the hinge 53, the hinge 53 may be engaged to allow the door 48 to swing open.
• One embodiment of the hinge 53 may include a receiver on the door 48 and the frame 22 for receiving a pin, such that when the door 48 is moved to the point where the receivers are in alignment, a pin may be placed ⁇ n the receivers to join the door 48 with the frame 22 through the hinge 53, such that the door 48 may swing with respect to the frame 22.
• the door 48 may be attached Joy a hinge such that the door may be configured to swing without rolling a distance away from the partitions 24.
• Yet another embodiment of the apparatus 20 may be provided without a hinge.
• allowing the door 48 to move away from the partitions 24 before swinging open may allow the ribs 31 to clear the slots 15 in the column portions 14 of the structures 10. Otherwise, swinging motion of the door 48 may be impeded by contact between tine ribs 31 and slots 15 to make opening the door 48 difficult in some arrangements of: the ribs 31.
• FIG. 7 a side view of one embodiment of a partition 24 is shown.
• a cross-sectional view of the partition 24 taken along line A-A is shown in FIG. S.
• the partition 24 may include one or more brace members 54.
• the brace members 54 may be sized and positioned to provide strength to the partition 24. since the forces exerted by concrete in the apparatus 20 may be significant.
• a panel 56 may be positioned on an exterior surface of the partition 24.
• the panel 56 may include any variety of shapes or features desi red to be applied to the concrete structures 10.
• One embodiment of the panel 56 may include a plate or liner 58 for placing a surface treatment 13 on the concrete structure 10.
• the surface treatment may include any variety of textures or designs, such as designs of rock or brick, for example.
• Other e ⁇ nbodiments of the liner 58 may be substantially smooth, without any particular design.
• some embodiments of the liner 58 may include a continuous pattern or texture corrfigured to extend over the entire panel 56, whereas other embodiments of the liner 58 may have multiple patterns, or be con-figured to cover only a portion of the panel 56.
• One embodiment of the panel 56 may include an upper member 60, a lower member 62, a first side membeztr 64 and a second side member 66 for forming a frame or housing 70 around the liner 58 for holding the liner 58 in place.
• One embodiment of the upper member 60, lower member 62, first side member 64 and second side member 66 may be formed of plate steel, 3/16 inches thick, for example. However, d.t will be understood that various different materials having different dimensions may be used within the scope of thxe present disclosure to form the upper member 60, lower member? 62, first side member 64 and second side member 66. As shown most clearly in FIGS. 10-13, which depict side views of the upper member 60, lower member 62, first side ⁇ '' !
• tlhe housing 70 may be formed by an upper lip 72 on the upper member 60, a lower lip 74 on the lower member 62, a first side lip 76 on the first side member 64, and a second side lip 78 on the second side member 66. It will be understood that one embodiment of the upper lip 72, lower lip 74, first side lip 76 and second, side lip 78 may be formed of a turd.-angular shaped member" . However, it will be understood that the housing 70 may be formed of various different shaped members configured to receive the liner 58.
• the panel 56 may include a back wall behind the liner 58.
• any of seals, adhesi ⁇ ves, or attachment mechanisms may be used to maintain the liner 58 within the housing 70 and allow the liner 58 to be removed and interchanged with other Hiners for providing different surface treatments to the structures 10 to be formed.
• tlhat other embodiments of the panel 56 may be formed without the upper member 60, lower member 62, first side member 64 and second side member 66, such that the panel 56 may be formed in different configurations without a frame or border surrounding the liner 58.
• panels 56 may be selected having a surface treatment desired to be placed on structures 10.
• the doors 48 may be opened and the partitions 24 may be moved "to provide access to the partitions 24.
• the panels 56 may be joined with the partitions 24 and reinforcing steel may be placed in the apparatus for a particular structure 10, if desired.
• Adjacent partitions 24 may be moved to abut each other and reinforcing material may be placed in a subsequent cavity 26.
• the partitions 24 may be fastened in place using fasteners 68, as best shown in FIG. 3.
• One embodiment of the fasteners 68 may include pins receivable in the base 23 for holding the partit-Lons 24 in place.
• fasteners 68 may ⁇ '"""-irlciMI:'"Siif ⁇ 'ot ; !i l 3 ! -!r"' i l'lr l iLet ⁇ of fastening mechanism known in the art, including threaded rods having adjustable blocking members attached thereto.
• the rods may be pivotallv attached to the base 23 or the partitions 24 and the blocking members may be engaged with the other of the base 23 or the partitions 24 for adjustably blocking movement of the partitions 24.
• additional fasteners 69 as shown in dashed lines in FIGS. 3 and 5, may t>e used to fasten the partitions 24 in place.
• the additional fasteners 69 may include bolts extending through the exterior partition 24 on opposing ends of the apparatus 20. It will be understood ttiat the location, configuration and quantity of fasteners 69 may vary within the scope of the present disclosure. Moreover, it will be understood that any other type of bolt, latch, pin, clamp or fastener known in the art may be used to hold the partitions 24 in place within the scope of the present disclosure.
• wet concrete may then be poured into the top of the apparatus 20 from above to thereby fill the cavities 26. Once the concrete has hardened adequately, the partitions 24 may be separated and the structures 10 may be removed. It will be understood, that any variety of lifting mechanisms, such as cranes or lifts, may be used to remove the structures from the apparatus 20. Moreover, in some uses of the apparatus 20, it may be benef ⁇ cial to apply a suitable anti-sticking agent to the apparatus 20 prior to placing concrete in the apparatus 20 to facilitate removing the structure 10 from the apparatus 20. Once the structures are removed from the apparatus 20, the apparatus may be cleaned and used repeatedly to produce additional structures 10 in a controlled enviromment for shipping to a construction site for installation. The apparatus 20 may also be placed in any location as desired to facilitate construction or shipping of the structures 10.
• some embodiments of the present disclosure may include an apparatus tha_t may be configured to form a plurality of structures thst do not l!: "" !: i3tf ⁇ AAi i; ft5 ⁇ • “cfflfii ⁇ Urtions, such that a plurality of panels may be formed.
• Other embodiments of the present disclosure may include an apparatus that forms structures in the form of columns. Accordingly, any variety of structures, having different arrangements of columns and/or panels, ⁇ ia ⁇ be formed in accordance with, the principles of the present c ⁇ isclosure.
• other structures of various different conf ⁇ igurations may be formed that may not be considered to be either panels or columns, in accordance with the principles of the present disclosure.
• the apparatus 20 may be configured to receive concrete of various different varieties known in the art. Moreover, the apparatus 20 may accommodate reinforcing material or steel, commonly referred to as rebar, to construct structures 10 of various different designs and configurations.
• the arrangement of the cavity 2S may allow for reinforcing steel to be place continuously in the first portion 28 of the cavity 26 for forming the panel portion 12 of the structure 3_0 and the second portion 30 of the cavity for forming the column portion 14 of the structure 10, such that the panel portion 12 and the column portion 14 of the structure 10 can be tied together with the reinforcing steel .
• the apparatus 2O may also include any variety of vibrating mechanisms integrally or removably attached, to the apparatus 20 in various different configurations to facilitate dispersal of wet concrrete within the cavities 26.
• the apparatus 20 may;y be formed of any suitable materials known in the art.
• portions of the apparatus 20 may be formed of steel, and components of the apparatus 20 may be joined together using any suitable method known in the art, such as by welding or bolting, for example.
• the liner 58 may be formed of any suitable material for placing a texture or design on the concrete without bonding to the concrete such that the removed from the apparatus 20 without damage .
• a useful method of forming concrete structures may include the steps of:
• the method may also include selecting liners having a desired surface treatment to be placed on the structures and removably attaching the liners to the partitions.
• eacti structure 110 may be formed of reinforced concrete, and may include a panel portion 112, for forming a wall, such as s. fence or sound barrier, for example.
• the structure 110 may also form part of a retaining wall, building, or any other such construct.
• the panel portion 112 may include a surface treatment 113 or decorative pattern, such as stone or brick, for example , formed on an exterior surface.
• the structure 110 may also include a column portion 114 for supporting the panel portion 112.
• the column portion 114 may have an increased lateral dimension as compared to the panel portion to allow increased vertical and lateral support of loads as the loads are transferred to a footing, floor, or other support member.
• the column portion 114 may also include a slot 115 for receiving a panel portion 112 of a.n adjacent structure 110. Accordingly, a plurality of structures 110 may be joined together to form a wall of a desired length and configuration. It will also be understood that one embodiment of the present disclosure may include a column portion 114 that does not include a panel portion 112.
• the structure 110 may be supported on footings 116, also sometimes referred to herein as supports.
• the footings X16 may be formed in any manner known to those skilled in the art, such as cast in place reinforced concrete.
• a member 11V shown in dashed lines in FIG. 15, such as a substantially rzLgid member including an "I" beam, post, pipe, rod, or reinforced concrete member, for example, may be attached to the footing 116.
• some embodiments of the present disclosure may include a rigid member 117 embedded into the footing 116, or other embodiments may include rigid members 117 attached to the footing 116 by welding, bolts, or any other suitable method known to those skilled in the art.
• the rigid member 117 may be ireceived in W l with. the slot 115 of the column portions
• one embodiment of the present disclosure may include an opening 120 that may be contiguous -with the slot 115 such that there may be no structural separation between the opening 120 and the slot 115. Some embodiments may also include the placement of concrete within the opening 120 of the column portions 114 to provide additional support to the structure 110 once the concrete hardens. It will be understood that some embodiments of the rigid member 117 may make construction of tt ⁇ e structure 110 possible without the need for forming a reinfzorcing cage on site for receiving cast in place concrete to support the structures 110. Accordingly, the labor requirements for installing the structures may be reduced.
• FIG. 16 A break:-away top view of one embodiment of adjacent structures 110 is shown in FIG. 16. It will be understood that the structures 110 may be formed of pre-cast concrete. The structures 110 may also include reinforcing steel 118, as shown in dashed lines in FIGS. 16 and 17. It will be understood that the configuration of reinforcing steel 118 as well as the concrete formulation may be provided in any suitable manner known to those skilled in the art to provide suitable strength and durability characteristics for the structures 110. It will also be understood that some embodiments of the structure may not include reinforcing steel 118.
• the panel portion 112 and the column portion 114 may formed in any manner known to those skilled in thte art, such as by placing concrete in forms in a factory condition so as to produce the structures 110 under controlled conditions.
• One embodiment of the structure 110 may include the column portion 114 and the panel portion 112 as an integra.1 one piece member of unitary construction without joints.
• Other embodiments of the present disclosure may be cast in place at a construction site. i;,i'ii"" "ii .• • l ⁇ , ⁇ :::f i ⁇ irn on h i !l - ⁇ 'leFer-'i ⁇ cd' " w'r ⁇ ' "now to made to FIG. 18 to describe an Var-e embodiment of the present disclosure.
• the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, incILuding that illustrated in FIG. 18.
• FIG. 18 may contain many of the same features represented in FIGS. 15-17 and only the new or different features will be explained to most succinctly describe trie embodiments of the disclosure illustrated in FIG. 18.
• FIG. L8 illustrates a break-away top view of an alternative structure 110a having an opening 120a for receiving a rigid member 117 for supporting the structure 110a in an upright position.
• the opening 120a may be separated from the slot 115a such that the rigid member 117 may be separated from the panel portion 112a of an adjacent structure 110a. It will be understood that the size, shape and position of the opening 120a may vary in accordance with tb.e principles of the present disclosure.
• FIG. 19 A br-eak-away top view of an additional alternative embodiment structure 110b is shown in FIG. 19.
• the alternative embodiment structure 110b may be formed with a panel portion 112b and a column portion 114b.
• the column portion 13.4b may also include an opening 120b.
• the alternative embodiment of FIG. 19 may not incXude a slot. Accordingly, any adjacent structures 110b, if present, may be joined without being received within the column portion 114b.
• the column portion 114c may be formed without a panel portion or a slot.
• the structure 110c may include an opening 120c for receiving a rigid member 117 to support the structure 110c in an upright position.
• a fixrther alternative embodiment structure 11Od may be provided, without a panel portion and having a plurality of slots 115& , as shown in FIG. 21.
• panel portions may be pr-ovided separately from the structure 11Od, and the panel portions may be joined to the structure 11Od through the slots L15d. It will be understood that the quantity, configuration and position of the slots 115d may vary as desired in accordance with the principles of the present disclosure.
• the slots 115d may be formed on adjacent sides of the structure 11Od, as depicted by the dashed lines in FIG. 21, such that the structure 11Od may form a corner of a barrrier with panel portions extending perpendicular to each other .
• FIG. 22 a side view is shown of one embodiment of a footing 116 and a rigid member 117.
• the rigid member 117 ma ⁇ y be formed as an "I" shaped member in cross section.
• the rigid member 117 ⁇ na.y be formed of a round pipe member, or a polygonal post meirOoer, or any other shaped member known to those skilled in the art.
• the member 117 may have any suitable size within the scope of the present disclosure.
• the member 117 may Joe formed of steel or any" other suitable material known to those skilled in the art to provide a member 117 that may be substantially rigid. It will be understood that one embodiment of the member 117 may be formed of a material that may be substantially rigid at the time the structure 110 is installed on the footing 116. Accordingly, assembly of the structures 110 may occur rapidly without waiting for concrete within the openings 120 to harden, as would be the case if the member IL17 were formed of concrete cast within the opening 120.
• the footing 116 may be formed of a concrete material, cast in place or precast in a manner known to those skilled in the art. Moreover, the footing 116 may be sized and include steel reinforcement as is known in the art. As shown member 117 may be attached to the footing 116 by being embedded within the footing 116. It will be understood that the member 117 may be placed in wet concrete forming the footing 116 such that the concrete may bond with the member 117 to form a substantially fixed connection.
• the member 117 may be embedded into the footing 116 at various diffeurent depths depending on various factors such as the height o£ the structure 110, the spacing of the column portions 114, and the type of soil supporting the footing 116, for example.
• One example of the present disclosure may include a rigid member 117 that may be embedded approximately five feet in "the footing 116 and the rigid member 117 may extend anotherr four feet out of the footing 116 for supporting a structure 110 that may be eight feet tall.
• the footing 116 may be formed approximately two- three feet in diameter for example. Accordingly, it will be understood that the disclosure presented in FIG. 22 is schematic in nature and is not intea ⁇ ded to be depicted to scale.
• the features of the present disclosure may vary, incl ⁇ uding the dimensions of the rigid member 117, the structure 11-0, and the footing 116, as well as the depth the rigid member 3_17 may be embedded into the footing 116.
• the footing 116 may be formed with an opening into whrich the member 117 may be received when the footing is in a hardened condition.
• the member 117 may thereafter be fixed within the footing 126 in any manner known to those skilled in the art, or the member 117 may be retained in the footing due to gravity and/or friction.
• FIG. 23 a side view is shown of an alternative embodiment for attaching the member 117 to the footing 116.
• a plurality of fasteners 122 may be embedded in the footing 116 for attaching to a birace member 124 on the rigid member 117.
• the fasteners 122 may include bolts or ste'el" 1 U 1 OTb- 1 HaV 1 IrIg- 8 S- *4 threaded end for receiving a nut 126. It will be understood that any number of fasteners 122 may be utilized to create a. suitable connection between the footing
• the brace 124 may be formed as an angle member or flat member joined to the rigid member 117 in any suitable manner known in the art.
• tJhe brace member 124 may be welded or bolted to the rigid member
• the brace member 124 may have openings for receiving the fasteners 122 therethrough. Once tine fasteners 122 are received through the brace member 124, tfcie nuts 126 may be cinched tight to fixedly attach the rigzLd member 117 to the footing 116.
• a side view is shown of an another alternative embodiment for attaching the member 117 to the footing 116.
• a first plate 127 may be joined to the member 117, such as by welding.
• a second plate 128 may be joined with the footing 11.6, such as by being embedded into thie footing 116. It will be understood that the second plate 128 may be embedded into the footing 116 so as to protrude abov ⁇ e an upper surface of the footing 116, or alternatively, thxe second plate 128 may be even with the upper surface of thre footing 116, or the second plate may be positioned below ttxe upper surface of the footing 116.
• the first plate 127 may b>e welded to the second plate 128 to thereby join the member 117 with the footing 116.
• the column portion 114e may include a slot 115e for receiving a panel portion of an adjacen ⁇ fc structure 110 similar- to the embodiments previously discussed .
• the column portion _Ll4e may also include reinforcing steeIL 118e, shown in dashed lines, such as rebar.
• An angle membe-ir 129 may be joined to the column portion 114e to assist in supporting the column portion in an upright position.
• the angle member 129 may be welded to the reinforcing steel 118e, 129 may be embedded into the colu ⁇ nn portion 114e, or the angle member 129 may be joined with tne column portion 114e in any other manner known to those skilled in the art.
• the angle member 129 may extend around a bottom corner of the slot 115e so as to provide a surface for joining with a plate 131 joined with the footing 116.
• the plate 131 may be embedded in the footing 116, or joined with the footing 116 in any other manner known to those skilled in the art. It will be understood that the angle member 129 may be welded to the plate 131 to support the column portion 114e in -an upright orientation.
• FIG. 26 a side view is shown of a further embodiment of a connection between a column 130 and a footing 116.
• the column 130 may form part or all of thie structure 110, or the column 130 nxay be representative of a rigid member for supporting a structure 110 in an upright position.
• a first plate 132 may be joined to the column 130 and a second plate 134 may be joined to tlhe footing 116. The first plate 132 may then be joined to tlhe second plate 134 by welding, bolting or any other suitable attachment mechanism known to those skilled in the art.
• first plate 132 may be joined with the column 130 using anchors 136 embedded into the column 130, or the first plate 132 may itself be embedded into the column 130, or the first plate 132 may be joined with the column 130 in any other suitable manner known to those skilled in tlhe art.
• second plate 134 may be joined with tlhe footing 116 using anchors 136, or the second plate 134 may Ibe joined with the footing 116 using any other attaching method known to those skilled in the art.
• tl ⁇ e first plate 132 may Ibe attached to the footing 116 using fasteners 122.
• the fasteners 122 may be embedded into tlhe footing 116 similar to the embodiment of FIG. 23 discussed previously.
• the first plate 132 may include openings for ⁇ " ⁇ crelv ⁇ nlg 1 " ⁇ HeTM ! f3liSliS t rs 122 and nuts 126 may be threaded onto the fasteners to attach the column 130 to the footing 1X6.
• the structure 110 may be constructed! on site or precast in. a factory setting under controXled conditions.
• the structure 110 may be formed to inclucle a desired surface treatment such as a brick or stone wall , for example.
• the footing or support 116 may typically be formed in place at the construction site.
• the member 117 may be attached to or embedded in the footing 116 in a des ⁇ red orientation to ensure that the structure may be oriented! as desired.
• the structure 110 may then be lifted such that the member 117 may be received in the opening 120. This may typically take place as the structure 110 is unloaded from a vehicle transporting the structure 110.
• a crane or other lifting device may be used to lift the structure 110 and lower the structure 110 over the member 117 onto the footing 1.16.
• Welding, bolting, and/or placement of concrete in the opening 120 may be used, for example, to fix the structure 110 to the footing 116.
• An adjacent structure 110 may be installed! in a similar fashion, with the panel portion 112 received in the slot 115. AccordingLy, a concrete column, panel and support system may be easily constructed to provide an aesthetically pleasing barrier.
• an alternative embodiment of the present disclosure may include two or more of the structures 110 stacked on top of each other.
• a rigid member 117 may extend beyond an entire height of the bottom structure 110 up through a portion or all of the height of an upper structure 110.
• one embodiment of the present disclosure may include a rigid member 117 extending from the footing 116 up to half way through the height of an upper structure 110.
• the upwardly stacked structures 110 may be supported in various heights and configurations.
• the structures discLosed herein may be formed of various materials, including concrete and/or filler materials, such as fiberglass, chopped glass or any other suitable material, that may be bonded or solid-Lfied into a hardened material with a cement or bonding agent, such as a resin.
• the apparatus for forming structures as disclosed herein may be configured to be compatible with various such construction materials.
• any structure, apparatus, or system for attaching a concrete structure to a support that performs, functions the same as, or equivalent to, those discLosed herein are intended to fall within the scope of a means for attaching a concrete structure to a support, including those structures, apparatuses, or systems for attaching that are presently known, or that may become available in the future. Anything that functions the same as, or equivalently to, a means for attaching a concrete structure to a support ffalls within the scope of this element.
• a useful method of attaching a structurre to a support includes the steps of: (a) attaching a substantially rigid member to a support;
• a structural system th.at may include a column portion integral with a panel portion of the structure.
• Another feature of one aspect of the present disclosure is to provide a structure that may be supported in an upright orientation, by a substantially rigid member.
• various features of the present disclosure are grouped together in a single embodiment for the puzrpose of streamlining the disclosure. This method of discILosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.

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• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
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• 2005
  • 2005-10-27 CA CA2588112A patent/CA2588112C/en active Active
  • 2005-10-27 WO PCT/US2005/039009 patent/WO2006047754A2/en active Application Filing
  • 2005-10-27 AU AU2005299567A patent/AU2005299567B9/en not_active Ceased
  • 2005-10-27 MX MX2007006196A patent/MX2007006196A/es unknown
  • 2005-10-27 EP EP05825001.0A patent/EP1805378A4/en not_active Withdrawn
• 2007
  • 2007-05-25 CR CR9152A patent/CR9152A/es not_active Application Discontinuation

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