ZA201008023B - A jig tower,a related construction method,and a related building element - Google Patents

Description

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THIS INVENTION relates to a jig tower, a related construction method, and a related building element.

A building element, as referred to herein, is typically a building block such as a brick, a . block of stone, or the like. - | oo oo

According to a first aspect of the invention there is provided a jig tower for use in constructing a column, the jig tower including an elongate central support and, along the : length of the support, a series of spaced apart arrangements of locating formations, in : which: oo : each locating formation is configured for supportively engaging a matching building element, in an upright, operative configuration of the jig tower; . in each arrangement of locating formations, the locating formations are angularly , spaced about a longitudinal axis such that, in the operative configuration, building elements engaged by the respective locating formations in the arrangement will be correspondingly spaced about the axis; and : the spacing of the respective arrangements of locating formations is such that, in the operative configuration, the building elements engaged by each arrangement of locating formations will form a course of a column. oo

The configuration of each arrangement of locating formations may be such that, in the operative configuration, it will be peripherally enclosed by an arrangement of matching building elements engaged by the locating formations.

The jig tower may be configured such that, in the operative configuration, arrangements of building elements held by the respective arrangements of locating formations will define courses defining between them gaps that can be filled with mortar. The building elements may thus be secured to each other by means of mortar to define a column. As will become apparent hereinafter, the jig tower may serve to arrange building elements in an aesthetically interesting or appealing arrangement in a column. | -

The respective arrangements of locating formations may be angularly offset with respect to one another in a predetermined pattern so that, in the operative configuration, matching building elements engaged by the respective locating formations will be correspondingly arranged in a pattern extending along the height of the column. The pattern may, for example, be a helical pattern. :

The elongate central support may comprise a single length of pipe. Alternatively, the jig tower may include a set of stacked jig segments, each defining a part of the operative - height of the jig tower. B oo

Each locating formation may include a dowel projecting outwardly from the elongate : central support and receivable in a complementary passage defined in a building . element. | :

According to a second aspect of the invention there is provided a set of jig segments that are stackable to form a jig tower for use in constructing a column, the jig tower including an elongate central support and, along the length of the support, a series of arrangements of locating formations, in which: - each locating formation is configured for supportively engaging a matching building element, in an upright, operative configuration of the jig tower; in each arrangement of locating formations, the locating formations are angularly spaced about an operatively upright axis such that, in the operative configuration, : building elements engaged by the respective locating formations in the arrangement will be correspondingly spaced about the axis; and the spacing of the respective arrangements of locating formations is such that, in the operative configuration, the building elements engaged by each arrangement of locating formations will form a course of a column.

In a first embodiment of the set of jig elements, each jig segment includes: a central support segment for forming a segment of the central support of the jig tower; )

® an upper stacking formation and a lower stacking formation permitting stacking of the jig segment along with the other jig segments on a suitable base to define the jig : tower; and : at least one of the arrangements of locating formations of the jig tower.

The at least one of the arrangements of locating formations of each jig segment may be a single arrangement and each jig segment may have an effective height corresponding : to the height of a matching building element and mortar layer. : = The stacking formations of the jig segments may be configured to provide, in the jig oo tower, at least one stacked arrangement of the jigs in which each two successive jig segments are angularly offset with respect to each other. The at least one stacked arrangement may comprise different stacked arrangements in which the angular offset “between each two successive jig segments is adjustable. In the first embodiment, each two successive jig segments may include in one of the upper stacking formation of the one segment and the lower stacking formation of the other a series of angular offset guides, each associated with a different angular offset position of the jig segments relative to each other. Each of the angular offset guides may define an interlock formation providing for the jig segments to be interlocked in the associated angular offset position. -

In the first embodiment, the central support segment of each jig segment may include a : cylindrical body, having an operatively vertical axis, with the locating formations projecting outwardly from the cylindrical body. The cylindrical body may be a length of pipe. a.

Each jig segment may include an alignment formation for receiving therethrough a straight, elongate element for aligning the jig segments. In the first embodiment, such alignment formation may be an inner tubular member, coaxial with the cylindrical body of the element and a top edge and a bottom edge of the cylindrical body may . respectively define the upper stacking formation and the lower stacking formation. A top end of the inner tubular member of each jig segment may stand proud of the top edge of its cylindrical body and a bottom end of the inner tubular member may be recessed with respect to the bottom edge of the cylindrical body, thereby to prevent inadvertent inversion of the jig segment, in use.

Each locating formation of each jig segment may include an outwardly projecting dowel, 5 the dowel being receivable in a complementary passage or socket defined in a building element. Such a socket may, for example, be defined by means of drilling or by casting it into the building element. :

According to a third aspect of the invention there is provided a method of constructing a - 10 column, the method including: SE : Co stacking a number of jig segments on a suitable base to define a jig tower, each jig segment including an arrangement of locating formations, each locating formation for engaging a matching building element, the locating formations being angularly spaced about a vertical axis; and . : engaging a matching building element with each locating formation to peripherally enclose the jig segment and to define courses of the building elements to define the column. - In the method, the configuration of the jig segments may be such as to define gaps between the courses of the building elements, the method including filling the gaps with mortar. The method may include inserting spacers between at least some of the building elements to level them. -The method may include angularly offsetting the jig segments with respect to each other thereby to angularly offset different courses of the building elements with respect to each other to define a pattern along the height of the column.

The method may include constructing a suitable base or foundation, anchoring an elongate element in the base or foundation in a vertical orientation, and aligning the jig segments along the height of the elongate element in a stacked configuration.

According to a fourth aspect of the invention there is provided a building element suitable for use with a jig tower according to the first aspect of the invention, the building

PY element defining a locating formation complementary to a locating formation of the jig tower.

The locating formation of the building element may be a passage extending into the building element from an operatively inner face thereof,- the passage being complementary to a locating formation of the jig tower where the locating formation is an outwardly projecting dowel. The building element may be substantially parallelepiped shaped. The passage may be perpendicular to the operatively inner face. : : 10 According to a fifth aspect of the invention there is provided a method of making a - building element according to the fourth aspect of the invention, the method including moulding the building element in a mould from a settable material, the passage being defined by a dowel formation embedded in the settable material. The dowel formation may protrude from an inner surface of the mould. :

The Applicant believes that the invention provides a convenient and practical means for creating a column with an aesthetically pleasing shape. This will become apparent from the examples below and from the figures to which the examples refer. :

Further features of the various aspects of the invention will become apparent from the examples described below with reference to and as illustrated in the accompanying : ‘diagrammatic figures.

In the figures: - Figure 1 shows a plan view of a first embodiment of a jig segment of a set of jig segments, in accordance with the second aspect of the invention;

Figure 2 shows a section of the jig segment of Figure 1 at Il — II;

Figure 3 shows a side view of the jig segment of Figure 1 at Ill — III;

Figure 4 shows a 3D view of a jig tower, in accordance with the first aspect of the invention, including the set of jig segments, all identical to the jig segment of Figure 1;

Figure 5 shows various steps of a method of constructing a wall that includes columns constructed in accordance with the method of the third aspect of the invention;

Figure 6 shows a side elevation of a column of the wall of Figure 5, the column including the jig tower of Figure 4 and a plurality of courses of building elements, in

, accordance with the fourth aspect of the invention, in the form of bricks engaged with the jig tower;

Figure 7 shows section VII — VII of Figure 6;

Figure 8 shows side elevations of different columns that can be constructed, in accordance with the method of the third aspect of the invention, by using different configurations of the jig tower of Figure 4;

Figure 9 shows a partial cross-section of two of the jig segments of the jig tower of

Figure 4 and an H-shaped interlock member interengaging the jig segments;

Figure 10 shows a 3D view of one of the bricks of Figure 6; and : :

Figure 11 shows a 3D view of a mould used in a method, in accordance with the fifth aspect of the invention, of making a brick. =

In Figures 1, 2, and 3, an embodiment of a jig segment, in accordance with the second aspect of the invention, of a jig tower, in accordance with the first aspect of the invention, is designated generally by the reference numeral 10.1. : The jig segment 10.1 includes: : a round cylindrical central support segment 12 in the form of a length of pipe 14, defining a central axis 16; four radially outwardly projecting locating formations in the form of dowels 18, angularly spaced at 90° about the cylindrical central support segment 12 at an equator of the jig segment 10.1; and SE an alignment formation in the form of a inner tubular member 22, coaxial with the cylindrical central support segment 12 and interconnected therewith by an arrangement of spokes 24.

The length of the cylindrical central support segment 12 is 85 mm, i.e. the height of a compatible brick of 75mm plus a mortar layer of 10mm. Its outer diameter is 114mm.

A top of the jig segment 10.1 defines an annular top edge 26, which is an upper stacking formation. A bottom edge 28 is a lower stacking formation.

A top end 23.2 of the inner tubular member 22 stands proud of the top edge 26 and a bottom end 23.1 of the inner tubular member 22 is recessed with respect to the bottom

® edge 28. This prevents inadvertent inverted installation of the jig segment 10.1 in a : stacked arrangement.

The length of pipe 14 defines in the upper edge 26 a series of upwardly open slots 30 and in the bottom edge 28 a slot 32. The slots 30 are at predetermined, varying angular spacings as indicated in Figure 1. As will become apparent from the remainder of this description, the slots 30 and 32 serve as guides and also as interlock formations for interlocking the jig segment 10.1 in any particular selected angular offset position with respect to another identical jig segment. oo oo oo

In Figure 4, a jig tower 35 is shown supported on a foundation 56, the jig tower including: oo a central vertical alignment member in the form of a pipe or rebar rod 34; and a stacked arrangement of jig segments 10 including the jig segment 10.1 and twenty other identical jig segments 10.2.

In this figure, the slots 30 and 32 of Figure 3 are omitted, merely for simplicity of the figure. B | oo

The features of the jig segment 10.1 above are incorporated by reference with respect to each of the jig segments 10.2. - With reference to Figures 2, 3, and 4, using the respective slots 30 and 32 as guides, each of the jig segments 10.2 is offset a predetermined angular offset relative to the jig segment below about a vertical axis defined by the rod 34. The slots 30 and 32 may also be used as interlock formations to angularly lock the jig segments with respect to each other. Such locking may be achieved by means of H-shaped interlock members, as shown in Figure 9 and described below, placed on each jig segment 10.1 or 10.2 where required before placing the one above it. The dowels 18 thus in essence define four helical series along the height of the jig tower 35.

In the jig tower 35, the cylindrical central support segments 12 (see Figures 1 to 3) thus together define an elongate central support 37. The elongate central support 37 is filled with concrete 39 (see Figure 7), which will set to strengthen the jig tower 35.

An alternative embodiment of the jig tower of the invention (not shown) may be outwardly identical to the jig tower 35, except that in the central support a single length of pipe may be substituted for a number of consecutive central support segments 12, even for all the segments. oo

Figure 5 shows steps in a method of constructing a security wall, the method involving the construction of three columns, in accordance with the method of the third aspect of the invention. In Figure 5, reference is made also to features appearing only in earlier figures. _ | -

In Figure 5(a), natural ground 50 has been cleared.

In Figure 5(b), the ground has been excavated to reduced levels 52 and 54 and : compacted with a plate compactor.

In Figure 5(c), a concrete foundation 56 has been cast and bottom ends of a series of five rods 34 have been cast into the foundation to project vertically from the foundation 56.

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In Figure 5(d), a stacked arrangement of jig segments 10 has been placed over each of three centre rods 34 to define jig towers 35. Similarly, jig segments 10.1 have been placed over the end rods 34 to define jig towers 60 similar to the jig towers 35, except that in the jig tower 60 the respective jig segments 10 are not angularly offset relative to each other.

In Figure 5(e) five columns 60.1 and 60.2 have been constructed, as will be outlined below with respect to one of the columns 60.2 shown in more detail in Figures 6 and 7.

In Figures 6 and 7, four building elements, in accordance with the fourth aspect of the invention, in the form of bricks 62 have been engaged with the respective dowels 18 of each of the jig segments 10 of one of the columns 60.2 to define a course 64 of bricks around each jig segment 10. The course 64 of bricks includes four bricks 62 in a square arrangement as shown, each brick 62 being engaged with one of the dowels 18 inserted into a socket 66 defined in the brick at a predetermined location. Such a socket may be formed in the brick 62 during manufacture or may be drilled into the manufactured brick.

Mortar 78 has been filled laterally in between the bricks 62 and between the different courses 64. oo : Spacers (not shown) may be used in required locations between courses 64 of bricks 62 to level them.

The angular offset of the respective courses 64 of bricks 62 creates the effect, shown in

Figure 6, of the courses spiraling along the height of the column 60.2.

Reverting to Figure 5(e), the end columns 60.1 have been constructed in a method similar to the construction of the columns 60.2, but involving rectangular courses of six : bricks each (not shown in detail). Each column 60.1 and 60.2 has been provided with an optional finishing cap 79.

In Figure 5(f), infill wall panels 80 have been conventionally constructed in gaps defined between the respective columns 60.1 and 60.2. :

In Figure 5(g), palisade fencing panels 84 have been installed in gaps defined between the respective columns 60.1 and 60.2 to complete a wall 86.

Figures 8(a) to 8(d) show different columns constructed in accordance with the method of the third aspect of the invention, by selecting different angular offsets of consecutive jig segments in the jig tower with respect to each other.

Figure 9 shows partial cross-sections of the jig segments 10.1 and 10.2 of the column 35 of Figure 4 and an H-shaped interlock member 90 engaged with the jig segment 10.2 via the slot 32 of the jig segment and with the jig segment 10.1 via one of the slots 30 of the jig segment. As such, the jig segments 10.1 and 10.2 are angularly locked with respect to each other by the interlock member 90.

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It will be understood that all of the jig segments 10 in the jig tower 35 of Figure 4 may be similarly interlocked by means of interlock members identical to the interlock members 90. :

The configuration of each jig segment may be adapted for creating a desired appearance of a column. There may, for example, be more than four locating formations for engaging a corresponding number of bricks or other building elements. Also, instead of the dowels 18, the locating formations may be cradles or teeth for supporting building elements thereon, depending on requirements. 0 - Co

The method of the third aspect of the invention and the jig segment and set of jig segments of the first aspect of the invention thus provide freedom for creating various shapes of columns that are meant to appeal to the eye.

In Figure 10, an embodiment of a building element, in accordance with the fourth aspect of the invention, in the form of a brick, is designated generally by the reference numeral . 62. The brick 62 has dimensions of approximately H = 75mm, W = 100mm, and L = 210mm.

The brick 62 is made of a suitable cementitious mix 94. The brick 62 defines therethrough two round cylindrical passages 96 for material saving. The brick defines an operatively inner face 98 and, on a centre line of the face and towards an end of the brick 62, a locating formation in the form of a blind passage 100 extending perpendicularly into the brick 62 from the face 98. oo

The brick 62 is. a mechanical equivalent of each brick 62, as described above, the only difference being that the brick 62 has no holes 96 defined through them. The bricks 62 and 62 therefore both are suitable for use in any method as described herein.

Figure 11 shows a mould for making the brick 62 of Figure 10, the mould being designated by the reference numeral 102. The mould 102 includes: ) a peripheral wall 104, including four side walls 104; a bottom wall 106; - rod or dowel 108, secured to the bottom wall 106; and B

PN two lengths of plastics tubing 110 extending through opposite side walls of the peripheral wall 104. :

The mould 102 defines therein a parallelepiped shaped space 107 within which the brick 62 is moulded. The dowel 108-is for forming the passage 100 in the brick 62. The lengths of plastics tubing 110 are for forming the respective passages 96 in the brick 62.

The peripheral wall 104 is removable from the base wall 106. oo

In order to make the brick 62, the peripheral wall 104 is placed on the base wall 106 and the lengths of plastic tubing 110 placed in position as shown. Wet cementitious mix is cast into the space 107 and the top surface of the cementitious mix is scraped flush with a top of the wall 104. Once the cementitious mix has set sufficiently, the lengths of tubing 110 are removed and the brick 62 is removed from the mould 102.

The above method of making the brick 62 is an example of the method of the fifth aspect of the invention. Several variations, as well as automation, of the method are possible. Moulding of the locating formation or passage 100 into the brick 62 avoids the ‘necessity of drilling such a passage into a brick. However, bricks with such passages defined by drilling may naturally be used in the method of the third aspect of the invention, as is also described above. :

Claims (37)

° lf 13 NL. CLAIMS

1. A jig tower for use in constructing a column, the jig tower including an elongate | central support and, along the length of the support, a series of spaced apart arrangements of locating formations, in which: each locating formation is configured for supportively engaging a matching “building element, in an upright, operative configuration of the jig tower; in each arrangement of locating formations, the locating formations are angularly spaced about a longitudinal axis such that, in the operative configuration, building elements engaged by the respective locating formations in the arrangement will be correspondingly spaced about the axis; and the spacing of the respective arrangements of locating formations is such that, in the operative configuration, the building elements engaged by each arrangement of locating formations will form a course of a column.

2 A jig tower as claimed in claim 1, in which the configuration of each arrangement of locating formations is such that, in the operative configuration, it will be peripherally enclosed by an arrangement of matching building elements engaged by the locating © 20 formations.

3. A jig tower as claimed in any of the preceding claims, which is configured such that, in the operative configuration, courses of building elements held by the respective : arrangements of locating formations will define courses defining between them gaps that can be filled with mortar.

4. A jig tower as claimed in any of the preceding claims, in which the respective arrangements of locating formations are angularly offset with respect to one another in a predetermined pattern so that, in the operative configuration, matching building elements engaged by the respective locating formations will be correspondingly arranged in a pattern extending along the height of the column.

5. Ajig tower as claimed in claim 4, in which the pattern is a helical pattern.

6. Ajig tower as claimed in any of the preceding claims, in which the elongate central support comprises a single length of pipe.

7. A jig tower as claimed in any of claims 1 to 5, including a set of stacked jig segments, each defining a part of the operative height of the jig tower. :

8. A jig tower as claimed in any of the preceding claims, in which each locating formation includes a dowel projecting outwardly from the elongate central support and : receivable in a complementary passage defined in a building element.

9. A set of jig segments that are stackable to form a jig tower for use in constructing a column, the jig tower including an elongate central support and, along the length of the support, a series of arrangements of locating formations, in which: : each locating formation is configured for supportively engaging a matching building element, in an upright, operative configuration of the jig tower; in each arrangement of locating formations, the locating formations are angularly spaced about an operatively upright axis such that, in the operative configuration, building elements engaged by the respective locating formations in the arrangement will be correspondingly spaced about the axis; and the spacing of the respective arrangements of locating formations is such that, in the operative configuration, the building elements engaged by each arrangement of "locating formations will form a course of a column.

10. A set of jig segments as claimed in claim 9, in which each jig segment includes: a central support segment for forming a segment of the central support of the jig tower; E ° an upper stacking formation and a lower stacking formation permitting stacking of the jig segment along with the other jig segments on a suitable base to define the jig tower; and : at least one of the arrangements of locating formations of the jig tower.

11. A set of jig segments as claimed in claim 10, in which the at least one of the arrangements of locating formations of each jig segment is a single arrangement and each jig segment has an effective height corresponding to the height of a matching building element and mortar layer.

12. A set of jig segments as claimed in any of claims 10 to 11, in which the stacking formations of the jig segments are configured to provide, in the jig tower, at least one stacked arrangement of the jigs in which each two successive jig segments are angularly offset with respect to each other.

13. A set of jig segments as claimed in claim 12, in which the at least one stacked 100 arrangement comprises different stacked arrangements in which the angular offset oo between each two successive jig segments is adjustable.

14. A set of jig segments as claimed in claim 13, in which each two successive jig segments include in one of the upper stacking formation of the one segment and the lower stacking formation of the other a series of angular offset guides, each associated with a different angular offset position of the jig segments relative to each other.

15. A set of jig segments as claimed in claim 14, in which each of the angular offset guides defines an interlock formation providing for the jig segments to be interlocked in the associated angular offset position.

16. A set of jig segments as claimed in any of claims 10 to 15, in which the central support segment of each jig segment includes a cylindrical body, having an operatively vertical axis, with the locating formations projecting outwardly from the cylindrical body. :

17. A set of jig segments as claimed in claim 16, in which the cylindrical body is a length of pipe.

18. A set of jig segments as claimed in any of claims 10 to 17, in which each jig segment includes an alignment formation for receiving therethrough a straight, elongate element for aligning the jig segments.

19. A set of jig segments as claimed in claim 18, insofar as it depends from claim 16, in which, in each jig segment:

@ “the alignment formation is an inner tubular member, coaxial with the cylindrical body of the element; and a top edge and a bottom edge of the cylindrical body respectively define the upper stacking formation and the lower stacking formation.

[) . .

20. A set of jig segments as claimed in claim 19, in which a top end. of the inner tubular member of each jig segment stands proud of the top edge of its cylindrical body and a bottom end of the inner tubular member is recessed with respect to the bottom edge of the cylindrical body, thereby to prevent inadvertent inversion of the jig segment, © 10 inuse. : oo | | oo oo

21. A set of jig segments as claimed in any of claims 9 to 20, in which each locating formation of each jig segment includes an outwardly projecting dowel, the dowel being receivable in a complementary passage or socket defined in a building element.

22. A method of constructing a column, the method including: stacking a number of jig segments on a suitable base to define a jig tower, each jig segment including an arrangement of locating formations, each locating formation for engaging a matching building element, the locating formations being angularly spaced about a vertical axis; and engaging a matching building element with each locating formation to peripherally enclose the jig segment and to define courses of the building elements to define the column.

23. A method as claimed in claim 22, in which the configuration of the jig segments is such as to define gaps between the courses of the building elements, the method including filling the gaps with mortar.

24. - A method as claimed in claim 23, including inserting spacers between at least some of the building elements to level them.

25. A method as claimed in any of claims 22 to 24, including angularly offsetting the jig segments with respect to each other thereby to angularly offset different courses of the

“building elements with respect to each other to define a pattern along the height of the column.

26. A method as claimed in any of claims 22 to 25, including constructing a suitable base or foundation, anchoring an elongate element in the base or foundation in a vertical orientation, and aligning the jig segments along the height of the elongate element in a stacked configuration. oo

27. A building element suitable for use with ‘a jig tower as claimed in claim 1, the building element defining a locating formation complementary to a locating formation of the jig tower.

28. A building element as claimed in claim 27, in which the locating formation is a passage extending into the building element from an operatively inner face thereof, the passage being complementary to a dowel of a jig tower as claimed in claim 8, for receiving such a dowel.

29. A building element as claimed in claim 28, which is substantially parallelepiped : shaped. Co

30. A building element as claimed in claim 29, in which the passage is perpendicular to the operatively inner face.

31. A method of making a building element as claimed in any of claims 27 to 30, which includes moulding the building element in a mould from a settable material, the passage being defined by a dowel formation embedded in the settable material.

32. A method as claimed in claim 29, in which the dowel formation protrudes from an inner surface defined by a wall of the mould.

. 33. Ajig tower as claimed in claim 1, substantially as described herein with reference to and/or as illustrated in any of the accompanying diagrammatic figures.” . ’ lo) ) Co

. 34. A set of jig segments as claimed in claim 9, substantially as described herein with . reference to and/or as illustrated in any of the accompanying diagrammatic figures.

35. A method as claimed in claim 22, substantially as described herein with reference to and/or as illustrated in any of the accompanying diagrammatic figures.

36. A building element as claimed in claim 27, substantially as described herein with reference to and/or as illustrated in any of the accompanying diagrammatic figures.

37. A method as claimed in claim 31, substantially as described herein with reference to and/or as illustrated in any of the accompanying diagrammatic figures. DATED THIS 9" DAY OF NOVEMBER 2010 ‘ a & MS & ADAMS Co APPLICANT'S PATENT ATTORNEYS :