US2358147A - Concrete structure - Google Patents

Description

Sept. 12, 1944.

R. R. COLBURN CONCRETE STRUCTURE Filed Nov. 6, 1942 INVENTOR.

ZZa/W A TTo/A/gy.

Patented sept. 12, 1944 UNITED STATES PA'I'EN 'r' OFFICE.

4 Claims;

My invention relates generally to improvement in the art of building, and relates more specifically to improvements in concrete structures'and to an improved method of producing such structures.

Generally defined, .an object of the present invention is to provide a new and useful reenforced structure, and an improved method of producing the same. y

It has heretofore been common and universal practice in the art of concrete construction, to utilize either of two standard methods of producing re-enforced concrete walls. In accordance with one of these prior construction methods, sections of the wall were prefabricated either in block or slab form suitably reenforced, and the sections were subsequently assembled and united in various ways to produce the final wall. This sectional method of construction, while resulting in the production of a wall having relatively uniform texture 'and strength, also introduced numerous joints between the sections which were subject to subsequent cracking and necessitated considerable repair; and in order to obtain the requisite strength in such sectional walls, it was also necessary to make the blocks and slabs rather heavy and bulky. The nal construction of these pre-fabricated sectional walls also involved Considerable skilled labor and other expense, thereby making the cost of these prior wall assemblages prohibitive for many purposes. In accordance with the other of these prior construction methods, preliminary wooden or metal forms were erected, reenforcing elements were properly positioned between the forms, and bulk concrete was nally poured into the forms around the re-enforcement and permitted to set, whereupon the casting forms were removed. Thismethod besides being laborious and costly, frequently resulted in the production of walls which were not of uniform texture throughout large areas, and the external sur- -faces were usually rough and required considerable ultimate ilnishing by coating or otherwise in order to provide smooth and presentable nal also due to the bulk and extreme weight of the final structures.

It is therefore a more specific object of my present invention to provide an improved monolithic re-enforced concrete wall structure, which is relatively light but extremely durable in construction, and which is also homogeneous in texture throughout its entire area. v

Another'speciflc object of the present invention is to provide a simplified and exceedingly strong building wall or ioor assemblage which can be formed primarily of suitably re-enforced concrete, without necessity of utilizing either precast blocks or' slabs, or complicated and costly pouring forms.

A further specii'lc object of my invention i's to provide a properly insulated and re-enforcedconcrete wall which is adapted to be utilized` in conjunction with standard window and door-'assemblages in order to construct -attractive and moderately priced buildings.

Still another specicobject of the invention is to provide improved supporting and re-enforcing means for concrete wall, ceiling and floor structures, which can be quickly and conveniently applied, and which will subsequently become an integral partvof and prevent undesiry semblages.

surfaces. The casting or pouring method fur-` thermore required the use of relatively skilled labor, and the enclosing forms did not permit inspection of the work until afterthe walls were ilnished and the forms had beenvremoved. Both oi these-prior methods of wall construction therefore possess many disadvantages and objections, and cannot be utilized for numerous purposes because of the expense involved and able cracking or other deterioration of the as- Another specific tures without objectionable joints, and with the aid of relatively simple forms which nally con-fl monolithic re-enforced concrete buildings in any expeditious manner, with least waste of material, and at minimum cost.

Still -another speciiic object of the invention is to provide a new and highly efficient method of constructing durable jointless one-piece reenforced concrete walls with simplified equipment, and in a manner which will permit unobstructed inspection of all portions of the work at all times. A

These and other specific objects, and advantages of my invention will be apparent from the following detailed description.

A clear conceptionof the various features constituting my present improvement, and of the method of producing walls of several types embodying the invention, may be had by referring object of the present inverntion is to provide a simpliiled and effective method of producing re-enforced concrete struc--` four inch centers between stud grooves I2 isv Fig. 3 is a similarly diagrammatic and fragmentary transverse vertical section through a typical floor or ceiling structure utilizing forms and reenforcements similar to that of the wall of Figs. 1 and 2';

Fig. 4 is an enlarged transverse horizontal section through a typical corner at the junction of two outer walls such as shown in Fig. 2;

Fig. 5 is a similarly enlarged transverse horizontal section through one of the columns or studs forming part Aof the improved wall of Fig. 2;

Fig. 6 is a likewise enlarged plan view of one of the re-enforcing rod supporting/'cleats used in the embodiment of the invention shown in Figs. .1 to 5 inclusive; and

Fig. '7 is a somewhat diagrammatic and fragmentary transverse horizontal section through a modified type of my improved wall structure.

While the invention has been shown and described herein as being advantageously applicable to several types 'of outside lwall assemblages and to only one form of floor or ceiling construction, it is not my desire or intention to thereby unnecessarily restrict the scope or utility of the improvement.

The present invention however does have special utility when applied to the construction of monolithic re-enforced concrete walls, and in accordance with the improved method, I first erect a single form having relatively extensive iiat surfaces lying in a common plane and separated by Vparallel upright grooves. Thereafter 1 temporarily but firmly position \at least'one upright re-enforcing bar or rod parallel and ladjacent to each groove but spaced from the form structure. I then attach a plane layer of foraminous re-enforcing material to the upright rods in spaced relation to the flat surfaces of the form sections and approximately parallel to the common plane thereof so that uninterrupted and plane portions of the foraminous layers span each groove. The monolithic wall is subsequently nally completed and finished by impacting concrete mixture at high velocity laterally against the flat form surfaces and within the grooves to an extent sufIicient to completely embed the rods and the foraminous material'within the layer ofconcrete.

Referring specifically to Figs. 1, 2, 4, 5 and 6 of the drawing, the type of initial backing form shown therein, may be produced primarily from sheets of insulation board or the like of standard twenty-four inch width. Each 'of the outer sheets 9 may have a three-inch strip I0 removed from one vertical edge thereof, and the sheets 9 and strips I0 may thereafter be secured to wooden spacer strips or bars II as shown in Figs. 1 and 2 to form upright parallel recesses or grooves I2 separatingrthe outer flat surfaces I3 of the successive sheets 9 which lie in a common plane. Each of theinner sheets I4 may be maintained at full twenty-four inch width, and' these sheets I4 may be secured to the wood bars II so as to provide sealed air spaces or chambers I5 between the sheets 9, I4 and the successive stud or column forming grooves I2. A durable and rigid backing form having twentythus provided.

The next step of my improved method is the attachment of the re-enforcing elements to the form assemblage just described, and this may be readily accomplished with the aid of cleats I6 such as shown in Fig. 6. These cleats I6 may be formed of sheet metal, and each cleat has a triangular portion I1 provided with nail holes I8 and adapted to be bent at right angles to the cleat along a score line I9, and is also 'provided with a re-enforcing rod receiving opening 20. The cleats I6 may be nailed to the wood bars II in the manner shown in Figs. 4 and 5, with the openings 20 of the successive superimposed cleats in vertical alinement. Upright re-enforc- -sulting from the ing bars or rods 2| may then be inserted in the alined openings 20, and these rods 2l will be firmly positioned parallel and adjacent tothe grooves I2 but out of direct contact with the form. Foraminous re-enforcing material 22 such as welded wire mesh, in continuous sheet form, may thereafter be attached as by wiring, to the successive parallel rods 2| and also to the cleats I6 if desired, whereupon the re-enforcing assemblage is completed. Care Should be taken to havethe portions of the sheet material 22 which spans the open sides of the grooves I2 in substantially flat condition and devoid of kinks or indentations.

When the form and re-enforcement assemblage has been thus completed as illustrated in Fig. 1, it is ready for the concrete, and the nal concrete layer 23 may be impacted against the outer fiat surfaces I3 and within the recesses or grooves I2preferably with the aid of compressed air which delivers the fluent concrete mixture in the form of a spray from a portable gun at high velocity. The use of such av spray gun permits the concrete to be quickly and uniformly applied throughout the entire re-enforced and exposed area, and the use of compressed air as a conveying medium for the concrete aggregate is also advantageous since the cooling eiect reexpansion of the suddenly liberated compressed air enhances the drying and setting of the concrete. By virtue of the fact that the concrete receiving form is entirely open and free from obstruction on the side towhich the y ly visible for inspection, and the operator is thus able to produce a smooth and finished outer surface 24 on the concrete portion of the wall. After the concrete layerl 23 has been applied, the exposed surfaces of the inner sheets I4 may be coated with a layer of plastic, paint, or other surfacing material thereby completing the wall assemblage and producing a simple, compact and durable monolithic re-enforced concrete wall the strength of which is greatly enhancedby the successive studs or columns and which will not crack at the zones of these columns due to the plane and uninterrupted disposition of the foraminous sheet material 22 across the grooves I2. A

This method of re-enforced wall construction may also be advantageously applied to oors and ceilings of a building, as well as to outer and inner walls, as shown in Fig. 3. Since the walls are vertically disposed, whereas the floors and ceilings are disposed horizontally, it may be desirable to additionally re-enforce the latter by making the horizontal parallel beams or joists heavier and by applying additional re-enforcement therein. As illustrated in Fig. 3, the depth of the grooves I2' is increased by using wider spacer strips or bars and modied cleats I6' areapplied within each ofthe grooves I2. to support an additional re-enforcing rod 2|?. Otherwise, the floor or ceiling structuremay be the same as the wall structure, and the concrete layer 23 may be applied in the manner previously described to produce a simple, compact and durable monolithic re-enforced concrete floor or ceiling of great strength.

While the use of the sheets 9, |4 of insulation board, and of the wooden bars Il, is entirely satisfactory'for producing the improved re-enforced concrete structure by the improved method, it may in some cases be desirable to prefabricate portions 'of the forms and to somewhat enhance the durability and strength thereof by constructing parts of the forms of metal, plastic, or other material which is stronger than the insulation board and wooden strips. Such a modied wall assemblage is shown in Fig. 7, whereinV the open sided form is constructed of a series of strong pans or plates 25 of interchangeably similar structure, each having oiset flanges 26, 21 at its opposite -vertical edges adapted to overlap the adjacent flanges 21, 26 of theadjoining sec-v tions or plates 25. The iianges 26, 21,0f the prefabricated plates 25 are provided with a series of perforations adapted to be brought into alineconcrete slab, and poured concrete wall structures, are more homogeneousan'd of uniform texture' throughouttheir entire areas, and can be lmore rapidly assembled with the new method at greatly reduced cost and with relatively unskilled labor. The improved walls are also adaptable to presentbuilding methods and dimensions, by virtue of, the fact that insulation sheets 9, I4, or

pre-fabricated plates of standard widths, may.

be used so as to produce standard distances between the stud or loist centers, -thereby permitting thev use of standard wooden ormetal -window and door frames in conjunction with these concrete walls. Because of the fact that the improved forms are one-sidedand are entirely open land -free from obstruction on the side from ment with each other for the reception of eyelbolts 28, andthe coacting-plate flanges may be clamped togetherv by means of lock nuts 29 coacting Awith the threaded reduced ends of the eye-bolts, thus producing the successive stud or column forming grooves 30 between the alined.

plane outer surfaces 3| of the successive form plates 25. Re-enforcing rods 2| may be inserted within the alined eyes of the superimposed eyebolts 28 and welded wire mesh or other foraminous 're-enforcing sheet material 22 may be ,secured to the rods 2| and eye-bolts 28 in an obvious manner, and a concrete layer 23 may thereafter be impacted against the surfaces 3| and within the grooves 30 so as to completely embed the re-enforcing elements, as previously' described.

In order to provide air chambers or Spaces 32` within walls of the modied type, the extreme inner ends 34 of the eye-bolts 28, beyond the threading thereon, may be split, and each bolt may be. embraced by a spacer sleeve 33 between the lock nut 29 and the split end 34. Blanket 'insulation 35 may then be placed against the outer plate flanges 2l and about the sleeves 33, whereupon metal lath 36 or other foraminous sheeting may be positioned against the sleeves 33 over the ends of 'the eye-bolts 28 and fastened in place by spreading the split end 34 of .each bolt. 'Ihe modified wall structure may be` finally completed by impacting or otherwise applying plaster 31 or ne concrete mixture against the metal lath 36 and insulation 35, thus producing'v a simple, strong and extremely compact monolithic re-enforced concrete wall assemblage, which is exceedingly durable and of highly finished appearance. i

From the foregoing detailed description of several embodiments cf the improvement, it will be apparent that my present invention provides an which the re-enforcing elements are supported, it is easy to apply the concrete layer 24 uniformly since all portions of the work are at all timesvisible to the operator, and a smooth final outer surface 24 is also readily obtainable. Themcde of supporting the 1re-enforcing rods 2| and the disposition of the foraminous sheet material 22 ina plane approximately parallel to the outer surfaces I3 without irregularities at the grooves I2, are also important features of the present invention, and result in the provision of structures which will not crack or weaken at the studs and joists. The use of compressed air in order to impact the concrete against the forms and around the re-enforcing elements, is also desirable in order to enhance the speed of construction, andthe improved cleats I6 may be readily produced at moderate c`ost and can be quickly applied so as to elTectively support the re-enforcement. The improved method has :been carried on with a high degree of success, and is adapted to facilitate the construction of buildings of re-enforced concrete and at a minimum cost. l

While my improvement has been-shown and described herein as having been applied primarily to the construction of outer walls, floors, ceilings, and to one type of corner construction, the'improvedv method is applicable to the effective construction of interior and exterior corners, to the attachment of partitions to walls, to the constructionof internal partitions, to the formation of upper and lower plates; sills, lintels and other building details. The specific type of hardware used in applying the method to such details of construction, and of cutting and fitting variousv c elements without the use of tools, forms no spe-v ciflc part of the present application which covers primarily the improved wall or iloor structure and the method of producing such structures'.

It should therefore lbe understood that it is not de'sired to limit'this invention to the exact steps of the method or to the precise details of construction of the walls, herein shown and depans to form outwardly open approximately upright recesses, clamping elements rmly uniting each pair of overlapping ilanges and having vertically alined openings disposed outwardly beyond said recesses and beyond the common plane of said areas, re-enforcing rods confined within said vertically aimed openings, ioraminous sheet material suspended solely from said rods and elements and being disposed parallel to and spaced outwardly from said plane, and a layer of concrete impacted against said pans and concealing said elements and rods and foraminous material.

2. A re-enforced concrete wall, comprising, a

series of metallic pans each having a plane area and inwardly oil-set integral opposite side flanges overlapping the adiacent flanges of adjoining pans to form outwardly open approximately -upright recesses, insulation sheathing coacting with vertically alined openings, foraminous sheet material suspended solely from said rods and elements and being disposed parallel to and spaced outwardly from said plane, and a, layer of concrete impacted against said pans and concealing said elements and rods and foraminous material.

3. A re-enforced concrete wall, comprising, a series of unitary pans each having a plane area and inwardly ofi-set integral opposite side flanges overlapping the adjacent anges oi' adjoining i pans to form outwardly open approximately up-,fV right recesses, clamping elements iirmly uniting each pair of overlapping flanges and having vertically alined openings disposed outwardly be-/v yond said recesses and beyond the common plane of said areas, re-enforcing rods confined within said vertically alined openings, foraminous sheet material suspended solely from said rods and elements and being disposedv parallel to and spaced outwardly from said plane, and a layer of concrete impacted against said pans and concealing said elements and rods and foraminous material.

4. A re-enforced concrete wall, comprising, a series of unitary pans each having a plane area and inwardly off-set integral opposite side anges overlapping the adjacent anges of adjoining pans to form outwardly open approximately upright recesses, insulation sheathing coacting with the inner surfaces of the successive pairs of overlapping -flanges to provide enclosed air spaces within said pans, clamping elements firmly uniting e'ach pair of overlapping flanges with each other and with said sheathing and having vertically alined openings disposed outwardly beyond said,recesses and beyond the common plane of said areas, re-enforcing rods coniined with said vertically alined openings, foraminous sheet material suspended solely from said rods and elements and being disposed parallel to and spaced outwardly from said plane, a. layer of concrete impacted against said pans and concealing said f lements and rods` and foraminous material, and

a layer of cementitious material disposed against the inner surface of said sheathing.

RICHARD R. COLBURN.

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