WO2001029337A2 - Fabrication of complete segments of a structure - Google Patents

Abstract

A method and mold device (100) for fabricating whole segments of a finished structure in a closely controlled environment at optimal curing temperatures and with beneficial misting. The mold device (100) has a working surface (1) upon which the segments are fabricated. The mold (100) comprises a movable mechanism, including a pivot (3) and a rotation post (3a) resting and turnable on a rotation post base (7), which permits the segment components thereon, including any cladding materials (9), to be moved into virtually any position to utilize gravational settling forces in molding. The mold device further includes transport members for transport of the segment via mold transport wheels (5), while on the mold (100), to construction, storage or curing sites. The mold device (100) further includes peripheral holding and shaping borders (2), hold-down elements movable on tracks (20), and a lock-down holder (8) to control segment shape and movement.

Description

FABRICATION OF COMPLETE SEGMENTS OF A STRUCTURE

FIELD OF THE INVENTION

The present invention relates to building structures, and particularly to systems, methods, apparatuses and devices for off-site manufacture, and assembly of large discrete segments of a structure and transport to a construction site in the building of the finished structure

BACKGROUND INFORMATION The universally accepted building method for structures such as buildings and other edifices, using conventional materials, has not changed significantly in the past century This method generally encompasses the on-site incremental addition of the various components of the building or structure (e g , "brick by brick") Pre-fab structures wherein larger units are utilized on-site, are simply variations in scale of the 'brick by brick" procedure, but do not otherwise differ from the structures made of smaller unit segments In all of such procedures the building with small units and with the generally non-uniform or non-controlled application of adhesion materials such as mortar, particularly s under possibly inclement conditions, eventually results in both aesthetic and structural problems

Thus, the uncontrolled application of mortar, which is often incompatible in adhesion and expansion between the materials, results, for example in the introduction of integrity problems, particularly in areas subject to variations in ambient conditions such as temperature and weather conditions In addition common sequential piecemeal methods are time consuming, cumbersome, are often inexact, 0 and dirty and even subject workers and the proximate public to actual physical danger both during construction and even afterwards

Even with experienced masons and builders, building quality, aesthetic and other standards of accuracy, rep cability, and degrees of finish vary Standardly constructed structures are relatively rigid with little room for any structural leeway to compensate for variations This results in material shifting ^ with formation of cracks or worse which may affect structural integrity

A particular integrity problem arises with the additional application of structural or decorative cladding material on a base structure with minimized adhesion Conventionally, straps are used to secure cladding material to a base structural material, with the straps usually being installed in a staggered order every few courses Even when the cladding material is directly attached to the 0 supporting structure and even if straps are added in order to stabilize the cladding material, adhesion is deficiently minimal and the cladding materials relies on the integrity of surrounding units to maintain their own structural integrity In the event an individual cladding unit separates from the supporting structure and/or from its neighboring unit, there is nothing to prevent it, and or its neighboring unit from falling free Backup safety means for maintaining adhesion are minimal or non-existent 5 SUMMARY OF THE INVENTION

It is an object of the present invention to pre-construct large units of a structure, such as entire walls, entire rooms and even with separate segments of cladding material, at a site remote from a building structure site, under carefully controlled optimal ambient, shaping, treating and curing conditions for enhanced uniformity and fit of structure, and with means for transporting the formed 0 units to the structure site for incorporation into the building structure It is a further object of the present invention to provide fabrication or mold means with full positional orientation for optimal use of gravity in molding, shaping and setting, as well as with full perimeter shaping and holding control and with full material holding maintenance during shaping and wherein the mold means comprises said means for transporting the formed units to a construction site

It is yet another object of the present invention, to use sealing members between segments of the structure in the mold means to function as both seals and shock absorbers between the individual segments and for the structure as a whole, with construction of the building structure

It is a still further object of the present invention to utilize spacer means during, manufacture to form exact dimensioned volumes and uniform placement of mortar and the like

It is yet another object of the present invention to incorporate support pins by affixation thereof to cladding material to provide enhanced adhesion and support between cladding and base support materials

It is still yet another object of the present invention is to provide means for enhancing incorporation of infrastructure elements by means of pre-formed channels and paths in the respective segments

Generally the present invention comprises a system, method and device for the construction of complete major sections of a structure with improved integrity and aesthetics In accordance with the present invention, a specially adapted fabrication support structure with controlled orientation and transport means, hereinafter referred to as "mold" is utilized off-site under controlled conditions The mold is adapted to be of a sufficiently large size to provide support and fabrication control for significant sized unitaπly formed segments of a structure The mold is preferably adapted for utilization with computer controlled filling and conjoining of elements therein A material program controls the position and composition of added materials within the mold, as well as density and other material variables The mold comprises a support surface, peripheral shape and sizing means and material binding means to stationary maintain materials within the mold under construction conditions as well as during movement and transport operations A central point of the support surface is maintained at a distance from the ground by base support means which permits substantially complete stable movement of the support surface around said central point, such as from a normal position parallel to the ground to a vertical position relative to the ground Gravity is thereby utilized to provide selective compressive forces and the like to materials during setting to enhance structural integrity as predetermined and/or required

In operation, and in accordance with the method of the present invention, the following steps are utilized with the mold, preferably under ambient controlled conditions off-site from the actual construction site, in the controlled construction of building segments a) cladding materials, such as bricks, ceramics, Jerusalem stone, and the like, are placed, with the eventual outer surface face down, on the support surface, b) individual elements of cladding material are uniformly (or as specified) spaced from each other by spacing means positioned between the individual cladding elements adjacent the support surface, c) pin element(of a preferred contour) are optionally placed on the individual cladding material elements to for support and maintain spacing, d) a first adhesion material is filled in between the cladding material elements and which is bounded, shaped and/or supported at one side by the spacing means, e) a second adhesion material, which may contain additional amounts of the first material, is applied to the cladding material distal to the support surface to form the segment structure, f) infrastructure passages are installed or otherwise formed in either or both of the adhesion materials prior to the curing thereof, g) the structure segment is treated and cured under pre-determined controlled ambient conditions, and h) the structure segment is transported to the structure building site and integrated into the structure These and other objects, features and advantages will become more evident from the following discussion and drawings in which

SHORT DESCRIPTION OF THE DRAWINGS Figure 1 shows the mold of the present invention with cladding material laid out over a lower support member while an upper support and lock member is in the open position, Figure 2 depicts the mold in an upright/vertical position, Figure 3 depicts positioning of the mold, with angled segment, holding means and placement depending on the material used, with an optimum tilt for utilization of gravity in segment formation,

Figure 4 is an enlarged view of the section demarcated by line 14 of Figures 1 , showing cladding material laid over support members, with flexible spacers placed between or draped over support members and wherein pins are imbedded in the cladding materials with further depiction of relative position of structural bonding agent to intermediary bonding agent, pins and spacers,

Figure 5 is a view similar to FIG 4 with a variation of the flexible spacers and showing the relationship between support members to cladding material, pins, spacers, intermediary and structural bonding agents and inner surface of structure,

Figure 6 is a top view of Figure 1 with holding means of vertical, lateral and diagonal members for holding segment materials in place and leaving room for the creation of sleeves for windows, doors and other openings,

Figures 7 is a side section view taken along line 7-7 of Figure 6 showing the use and removal of a minor mold element in making a window opening,

Figure 8 is a perspective view of a mold element for producing channels/pathways or passages for infrastructure placement,

Figure 9 depicts rods that are designed to create pathways or passages in more than one direction,

Figure 10 shows two segments ready to be joined with their respective pathways lined up, Figure 1 1 is a side view of a model of the mold positioned in front of an adjustable apparatus that is a scaffold, both on tracks and having transporting elements, and Figure 12 shows two segments being attached to one another at a construction site DETAILED DESCRIPTION OF THE INVENTION

The adjustable structure fabrication device or mold preferably comprises means to permit fabrication of an individual segment using a single type of cladding material or an esthetically appealing combination of cladding materials The selected construction material is continually held in place prior to and throughout casting process thereby insuring superior bonding of materials and accuracy

In a further preferred embodiment, the mold comprises means to shape the perimeter contour as well as the total configuration and size of the segments with various shapes, patterns and designs as desired or specified

The holding members used to hold and maintain materials in place on the mold are placed vertically, horizontally and diagonally as optimally required for holding integrity

In a further embodiment of the invention, connection pins of the optimum curvature are utilized to grasp segments of the cladding material and bind them to other materials and/or to each other As a result, in addition to the usual adhesion of the surface of the cladding materials to the intermediary bonding agent, the pins are imbedded in the cladding material, and are set into, and adhere to the intermediary bonding agent and structural bonding agent to complete a full connection In the event the intermediary bonding agent separates from the cladding material surface, the pins, which are imbedded in the cladding material as well as both the body of the intermediary bonding agent and the structural bonding agent, provide secondary and tertiary backup adhesion support

Infrastructure placement of channels, pathways, mechanisms and equipment positioning is in any direction, as required, to permit precision and replicability

The fitted flexible spacer members applied over the mold's supporting surface and between cladding and other materials are preformed in a variety of size, shape and density of material, and are stocked to fit any design desired The spacers set the depth and gauge of grout lines as well as the space between the cladding materials and the mold The flexible spacers also provide protection to cladding materials and other materials and equipment from damage, including undesirable contact or friction between hard or otherwise damage prone materials Further, the spacers protect materials and equipment against discoloration and debris accumulation, common occurrences with prior art construction procedures The spacers provide the aesthetic features of improved symmetry and uniformity in the placement of the cladding material and the spacers also permit custom mortar placement thereon, beyond the capabilities of a master craftsman, by simplifying mortar placement with controlled width, depth and accuracy of course line

The mold of the present invention is preferably utilized off-site where custom structures can be efficiently made under controlled ambient conditions wherein

1 ) The temperature is kept at an optimum level whereby the segments cure evenly The chemical process (cement get hot at casting), which continues for about twenty eight days, is affected by temperature Accordingly controlling temperature to an optimum level decreases any likelihood that segments will be effected adversely 2) A steady stream of misting (optimum pressure, amount and temperature) water is applied to the segments during the slow curing process

3) On site, after transport of segments to the construction site, controlled use continues with transporters and other machinery - ON SITE - to hold and unite segments in the least damaging manner in preventing chipping or any unwanted trauma

Transport is effected within a short time frame with the use of specially created transport vehicles for transporting segments to the desired site of construction where the individual segments are bolted or otherwise connected to pre-arranged support members and/or each other

As an alternative to transport of the finished segments (some of which are interchangeable) can be cataloged and stored until needed

Since the segments are fabricated in a controlled environment, there is a high degree of uniformity with superior finished product of the structure The segments are united at the preferred location into a completed structure using any choice of materials or adhesives for maximum effect DETAILED DESCRIPTION OF THE DRAWINGS AND THE PREFERRED EMBODIMENTS The fabrication device or mold 100 shown in FIG 1 , is in a level position which, for many applications is a gravitationally favorable position Cladding material 9 is placed in any desired order and/or in accordance with architectural instructions onto platform 1 Cladding material 9 is any veneer material and/or outer or inner skin of any part of a building Platform 1 comes into contact with as much surface area as desired of the cladding material 9 on either or both of its face or back Platform 1 , along with any materials thereon, rest on chassis mold support 10 to thereby handle and distribute the weight and mass The weight of the upper section of the mold including building materials resting on mold support 10, are supported by mold framework support 4 Rotation post 3a provides both adjustable movement and additional support Rotation post 3a is also elevation means, permitting raising and lowering of mold and load The mold may be stationary and/or mobile, and in a mobile application, mold transport wheels 5 permit full movement of the apparatus In either mode, lower mold framework 12 supports the apparatus at its base Pre-determined vibration may be introduced to the mold in either the static position and/or when the mold is in motion, to facilitate settling

The mold operator is instructed regarding the composition of the segment, its desired appearance, arrangement and type of cladding material 9 and/or other relevant information In accordance with those instructions, segments or slabs of any material, tiles of marble/granite/ceramic Jerusalem Stone, bricks or other floor, roof, wall or any cladding materials are placed within the designated area of the mold and secured by lock down holder 8 and/or straps and border retaining elements 19, 21 and 22 (more clearly seen in Figure 6) In an application where a specific force is desirable, such as behind, above, below and/or between joint 6 and/or other parts of the segment or of cladding material 9, the mold can be moved into the appropriate position to accomplish this For example, in FIG 2 the on loaded materials are shown pushing down with near maximum pressure ultimately reaching rest support 17 but with less pressure distributed to other parts of the mold In the horizontal position, the segment perimeter guide and shaper 2 is fixed and locked in place to provide added lateral security to mold contents and shapes of the segments by confining and corralling all materials, bonding agents and equipment into the desired contour In the vertical position, perimeter guide and cladding lock 2 is used as shown in Figure 3

In Figures 4 and 5, spacers 16 are positioned around, between and/or under the individual cladding units 9 in accordance with instructions Spacers 16 insure uniform gapping, width and depth of joint 6, which is defined by the space between and around cladding material 9 Additionally, spacers 16 provide an effective seal that protects and preserves individual building material units and machinery from leakage caused by bonding agent 30 Spacers 16 also protect contents and/or mold and machinery by minimizing fπctional contact 33 thereby, reducing any potential damage Once spacers 16 are secure, pins 32 are inserted into cavities 31 which are inconspicuously located on the body of cladding material 9 Pins 32 are of any shape and gauge of the preferred material With pins 32 and spacers 16 in place and cladding materials 9 arranged in a preferred arrangement, lock down holders 8 and/or holders 19,21 or 22, shown in Figure 6, are optionally utilized Holders 19, 21 and 22 provide several holding options They can reach all parts of the mold by traveling along and locking onto independent tracks 20 & 20a and/or tracks 23 & 23a, by riding in, on or around the independent main tracks Tracks 20 and 23 are independently able to move and adjust around segment contours and can be removed in part or completely Tracks 20a and 23b are joined to form a framework for applications where added or specialty structural precision and/or stability is needed In cases where equipment or materials require special or additional grasping means, adjustable and/or retractable and/or expandable holding members 24 may be used, which members are especially effective in holding asymmetrical equipment

These holders may also be used to hold minor mold 25 in place in position within the mold in preparation for windows 29 or doors or other openings, equipment and other objectives Though minor mold 25 is designed to withstand great pressure from all directions it is adapted to be easy to remove after casting (Figure 7) Mold lock wedge 28 retains minor mold 25 fixed and square in the desired position before and during casting After casting, mold lock wedge 28 facilitates convenient removal of minor mold 25 without any undo pressure or damage to segment, materials, equipment or machinery Lock down holders 8,19,21 ,22 separately or in unison, hinged or not, help secure and retain the mold contents in place thereby permitting the mold to be freely moved without detrimentally affecting mold contents The mold can be moved, turned and tilted in all directions by virtue of pivot 3 rotation post 3a and wheels 5 The mold can roll forward and/or backward for complete access to all parts of the mold Rotation post 3a rests and turns within rotation post base 7 The mold may be brought to any position the upright position shown in FIG 2 for testing, inspection, or any other reason well before bonding begins The set up and layout of that which has been locked within the mold can be visually or otherwise examined or photographed (digitally for transmission), recorded and or checked electrically and/or via other sophisticated means for accuracy and satisfaction With final inspections completed, cladding material 9, spacers 16, pins 32 and other components in place, the mold may be brought into any desired position, preferably horizontal, as shown in FIG 1 for the introduction of intermediary bonding agent 30, shown in Figures 4 and 5 along line 14, as shown, between and/or over joints from the back of the facade of cladding material 9 uniting everything it comes in contact with During this application the exposed portion of pins 32 located at the exposed rear of cladding material 9 may be folded, bent or moved to a number of different positions as desired Spacers 16 affect gauge, depth, width, amount and shape of intermediary bonding agent 30's penetration into gaps 6 between, around and behind cladding materials 9

The aforementioned holders may also be used to secure channel mold 27 (FIG 8) in place Channel mold 27 is used to create any number and type of channels, grooves or impressions of the desired gauge, diameter or shape within segments or parts thereof Channel mold 27 is comprised of channel forming elements Additional channel forming elements 51 v (FIG 9) can be applied to run through the body of channel elements 51 to create grid like pathways, as needed, of channels that intersect each other thereby providing an open pathway access to virtually all parts of a segment and of the structure proper for electrical wires, pipes, etc The channels additionally have an insulation value and reduce the segment's weight Channel forming elements 51 v pass through aperture 39 in the body of channel forming element 51 If only channel forming elements 51 alone are used, aperture openings 39 may be closed by plugs 39a Aperture 39 and corresponding plug 39a may be at any angle within the body of channel forming element 51 or 51 v, thereby allowing the grid to be of any intersectional configuration Channel forming element 51 results in the forming of conduit/channel/pathways 41 (shown in Figure 10) into which infrastructure lines may be threaded Channel forming elements 51 v form pathways 41 v which are cross-over channels that intersect with other pathways to thereby permit infrastructure lines to reach all parts of the structure Channel forming elements 51 and 51 v may be comprised of flexible and/or inflatable tubing in application where a circuitous, serpentine, winding or any shape pathway is desired and may be removed by deflation at the appropriate time after casting In applications where channel forming elements 51 are rigid and straight, freeze break gears 52 are brought to bear with a turning action to break frozen seals or any jamming that may have occurred during or after casting The turning action that breaks the frozen seal also smoothes and enhances an unimpeded pathway for future infrastructure line insertion After intermediary bonding agent 30 has been poured (or even prior thereto), infrastructure equipment, such as channel mold 27, which produces pathways 41 ,41v, flexible tubing, gem boxes, junction boxes, re-bars, netting or other additives may now be placed in or on the mold Pathways 41 and 41 v, along with related junction boxes and splicing areas may be provided throughout the segments in more places than needed Some junction boxes may be exposed and used by homeowner immediately upon completion of assembly and erection of structure while others remain available for future use

When all necessary materials and equipment have been placed and secured, structural bonding agent 13 is introduced Structural bonding agent 13 can be comprised of, or contain, any additive to achieve the desired strength, insulation or other effect The additives and/or insulation may be introduced in several applications, before, after, or during casting of agent 13 Agent 13 holds materials together within the mold and also acts as structural reinforcement for the segments. In addition to holding together the mold contents, agent 13 provides the skeletal strength of the segments individually, and the structures collectively Exposed sections of agent 13 may be cast with esthetically pleasing facade After bonding agent 13 has been properly placed, vibration, such as by mechanical means, may be used to remove any trapped air therein. Bonding agent 13 and/or fluid contained therein may be jolted or the mold may be vibrated Alternatively, the entire mold may ride over a grating to effect quivering After this stage is completed, the mold is allowed to remain stationary until its load has hardened adequately for safe removal or the mold is moved to a desired location for an optional hardening phase

After bonding agent 13 has been placed and the segment sufficiently hardened, it is transported to a curing and storing facility where the segment is cured in the optimum manner under controlled conditions for a requisite amount of time The hardened segment can be transported by the mold itself or by other means, such as adjustable scaffold 35 shown in Figure 11 which may be used as transport means for segments and other equipment as well as a practical working platform All parts of the mold may be reached and worked on with use of an adjustable platform 37

Propulsion device 38 provides mechanical removal and transfer of the hardened segment from mold to scaffold or curing area and visa versa, with a smooth push of the segments without jarring Rotation post 3a provides upward and downward movement to assist in segment placement and transfer Scaffold 35 rests on wheels 5a adapted to turn and travel including on track or platform 1 1 , which leads, for example, to a curing area, storage area and/or building site Stabilizing rod 36 aids in transport by reducing top-heavy conditions and may also ride on track/platform 11

When the segments are sufficiently cured in the curing area they may be moved to a storage facility for cataloging and storage, or alternatively moved directly to the construction site for assembly An example of one method for joining segments is shown in Figure 12 Fastening means 26a comprises interfitting edge elements which mesh between separate segments including 9 The joining is not visible to view The addition of uniting bonding agent 61 adds strength to the bond between the individual segments as well as a measured and controlled quantity of rigidity, as desired

With the segments in place, locked and secured, infrastructure lines are pulled through conduit/channel/pathway 41/41v Whole complete or partial Units such as rooms 59 or smaller 56 (Fig 13) are integrated with established segments along with relevant accessories Hook up is accomplished at junction 57 Utilities and related fixtures and appliances with other conveniences are positioned and/or installed Windows 29 and doors 29a along with other accessories are snapped into place or otherwise installed with minimum effort into precise prearranged sleeves, openings or predetermined means Where applicable, these openings are pre-aligned Coining, and any adornments or decorative union and the like, may be applied inside or outside Moldings and decorative designs 44 or the like are installed for decorative purposes, for reasons of obscuring or camouflaging and/or any reason Finally, the last finishing touches are put in place The new structure is swept, painted, carpeted and the keys are handed to the new owner It is understood that the above description and drawings are merely exemplary of the present invention and that changes may be made without departing from the scope of the present invention as defined by the following claims.

Claims

What is claimed is

1 A method for the construction of at least one complete major section of a structure, at a site remote from a building site of said structure, said method comprising the steps of a) placing materials comprising said major section into a fabrication support structure mold, wherein said mold comprises i a support surface for supporting said materials, ii means for the controlled positional orientation movement of the support surface for said materials, and in means for the transport of said mold, with supported completed major section of the structure, b) forming said materials into said major section on said mold, and c) moving said mold with said controlled positional orientation movement means, to utilize gravity to provide selective compressive forces to said materials during setting, and wherein said mold comprises material binding means to stationary maintain materials within the mold during forming of the major section as well as during said controlled positional orientation movement and transport of

2 The method of claim 1 wherein the mold further comprises peripheral shape for forming said major section to a predetermined peripheral shape and sizing means for maintainθing size of said major section to a pre-determined size

3 The method of claim 1 , wherein ambient conditions during said construction of the major section remote from the building site ares maintained under controlled temperature and curing conditions, adapted to enhanced uniformity of the major section

4 The method of claim 3, wherein said ambient conditions include periodic misting of said major section during curing of said materials

5 The method of claim 1 wherein the major section is comprised of segments and wherein sealing members are positioned between the segments, with said sealing members comprising both sealing means and shock absorber means between the segments and wherein the sealing members are adapted to remain in said structure and to function as shock absorbers for the structure, when said structure is completed

6 The method of claim 1 wherein the major section is comprised of segments and wherein spacer means are positioned between said segments during forming of the material into the major section to provide substantially exact dimensioned volumes and uniform placement of structure material and connective material therebetween

7 The method of claim 1 , wherein major section comprises cladding materials adhered to base support materials in said mold, and wherein support pins are affixed to cladding material with said support pins being adapted to provide enhanced adhesion and support between cladding and base support materials with deployment of adhesive material therebetween

8 The method of claim 1 , wherein the major section is comprised of segments and wherein said segments are formed to comprise contiguous channels to provide paths for infrastructure elements within the major section 9 The method of claim 1 , wherein the method further comprises the steps of i) placing cladding materials, with the eventual outer surface thereof face down, on the support surface, j) spacing individual elements of cladding material by pre-determined distances from each other by spacing means positioned between the individual cladding elements and adjacent the support surface, k) filling a first adhesion material in spaces between the cladding material elements and which spaces are bounded, shaped and/or supported at a distal side by the spacing means, I) applying a second adhesion material to the cladding material distal to the support surface to form the segment structure, m) forming passages, adapted for subsequent infrastructure deployment therethrough, in any of the adhesion materials prior to the curing thereof, n) treating and curing the cladding materials and adhesion materials under predetermined controlled ambient conditions to form said major section, and o) transporting the major section of the structure to the structure building site and integrated in the section into the structure 10 The method of claim 9, wherein pin elements are placed on the individual cladding material elements for support of said adhesiθon materials and to maintain spacing between individual elements of said cladding materials, 11 A fabrication support structure mold for the construction of at least one complete major section of a structure, at a site remote from a building site of said structure, said mold comprising a) means for the controlled positional orientation movement of the fabrication support for said materials, b) means for the transport of said mold, with supported completed major section of the structure, c) a support surface, peripheral shape and sizing means and material binding means adapted to stationaπly maintain materials within the mold under construction conditions as well as during said controlled positional orientation movement and transport operations 12 The mold of claim 11 wherein said controlled positional orientation movement means, is adapted to permit movement of said major section to permit gravity to provide selective compressive forces to said materials during setting

13 The mold of claim 1 1 wherein a point of the support surface centrally located thereon is maintained at a distance from the ground by base support means to thereby permit substantially complete stable movement of the support surface around said central point, from a position parallel to the ground to a vertical position relative to the ground