Static structures (e.g. – buildings) – Facers; e.g. – modules – mutually bonded by internal settable... – Laterally related modules; e.g. – back-to-back
Reexamination Certificate
1999-07-28
2001-10-16
Stodola, Daniel P. (Department: 3634)
Static structures (e.g., buildings)
Facers; e.g., modules, mutually bonded by internal settable...
Laterally related modules; e.g., back-to-back
C052S309700, C052S426000, C052S745100
Reexamination Certificate
active
06301851
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to construction systems and, more particularly, to construction systems which employ a plurality of connectable precast modular units which are transported to a building site and erected to construct a building structure, such as a basement, a garage or a floor level suitable as part of a dwelling, or to construct a fire cistern (snow-melting tank), a stilted foundation and the like. The present invention also relates to a method and apparatus for forming precast modular units, and to a precast modular structure and method for constructing the precast modular structure.
2. Background Information
Heretofore, when a basement is being prepared for construction of houses, for example, the ground at a construction site of the basement is excavated, underground water is treated, concrete is poured to form a floor, reinforcing rods are carried to the site and assembled together with temporary frames for forming retaining walls, and concrete is then poured to form the retaining walls. Thereafter, while curing of the concrete is carried out to ensure strengthening of the concrete, a temperature control operation is conducted until the concrete is hardened.
The foregoing conventional method of preparing a basement has the following problems. After the concrete is cured, the temporary frames are disassembled and removed from the site, the concrete surface is repaired, and then the exterior of the concrete structure is entirely waterproofed. Such operations are complicated and take about 3 to 4 weeks to complete. Furthermore, concrete beams, a floor for reinforcement, etc. are required to be constructed at the upper portion of the basement in order to withstand the soil pressure from the exterior. As a result, there arises various problems, for example, poor operational efficiency, prolonged construction and increased cost.
Moreover, masonry and concrete constructions are difficult on building sites in some weather conditions. During cold weather, on-site masonry and concrete construction are generally impossible. On-site masonry and concrete construction can also be delayed by water and snow. These delays increase construction costs.
Methods of constructing basement or garage structures by integrally forming walls, ceilings and floors into a box-like shape and then transporting them to an installation site are known. However, such methods are difficult to carry out because of the difficulty in transporting the basement or garage structure to the installation site due to the large weight of the structure. Accordingly, it has been necessary to reduce the size of such prefabricated structures in order to reduce their overall weight for transportation purposes. As a result, such prefabricated structures enclose relatively small interior spaces and therefore fail to provide sufficient space for storage or living.
SUMMARY OF THE INVENTION
The present invention is directed to precast modular units, a method and apparatus for forming precast modular units, and to a precast modular structure and construction method thereof which overcome the foregoing drawbacks in the conventional art.
It is an object of the present invention to provide precast modular units made of a construction material, such as concrete, that can be easily and economically transported to a construction site and erected.
Another object of the present invention is to provide a method and apparatus for forming precast modular units economically and efficiently using a construction material, such as concrete.
Another object of the present invention is to provide a precast modular structure having precast modular units which can enclose large interior spaces for storage or living.
A further object of the present invention is to provide a method for constructing a precast modular structure which increases the efficiency of on-site operation and which can be accomplished in a short period of time as compared to conventional construction methods.
The foregoing and other objects of the present invention are carried out by a precast modular unit system comprising a plurality of generally different precast modular unit sets each having a plurality of identical precast modular units. The precast modular units of each precast modular unit set have connecting surfaces each for connection to a corresponding connecting surface of one other identical precast modular unit or to a corresponding connecting surface of one of the precast modular units of another of the precast modular unit sets to construct a precast modular structure having a predetermined configuration.
Preferably, the precast modular units of each precast modular unit set are made from a construction material, such as concrete. Each precast modular unit of each precast modular unit set comprises a wall portion, a base portion extending from the wall portion, and connecting means disposed on the connecting surfaces for connecting the precast modular units to one another.
Preferably, the precast modular units of one of the precast unit sets comprise wall sections, and the precast modular units of another of the precast modular unit sets comprise corner sections. The connecting surfaces are disposed on right and left side surfaces of each of the wall and corner sections. Preferably, a plurality of reinforcing members are embedded in the wall and base portions of each of the sidewall and corner sections for reinforcing the sections.
In a first embodiment, each of the wall and corner sections has a flange portion extending from a surface thereof for strengthening the section. In a second embodiment, the base portion of each of the wall and corner sections comprises an inner base portion and an outer base portion extending inwardly and outwardly, respectively, from the wall portion. In a third embodiment, each of the wall and corner sections according to the second embodiment has a flange portion for strengthening the section.
In another aspect, the present invention is directed to an apparatus for forming precast modular units. The apparatus comprises at least two modular forms configured to be arranged and interconnected in spaced-apart relation to one another, a plurality of reinforcement members disposed in each of the modular forms, a plurality of connecting members each integrally connected to one of the reinforcement members and extending from side edges of each of the modular forms, and a molding plate configured to be arranged and interconnected between the modular forms.
Preferably, each of the modular forms comprises a pair of opposite, spaced-apart frames and a hollow stepped portion extending from the frames, the reinforcement members being disposed between the frames and in the hollow stepped portion. The frames, the hollow stepped portion and the reinforcement members of each of the modular forms define spaces within the modular form which are configured to receive and allow flow of a construction material, such as concrete, being poured therein to form the precast modular units.
In another aspect, the present invention provides a method of forming precast modular units. At least two modular forms are provided, each having side edges, a plurality of reinforcement members, and a plurality of connecting members each connected to one of the reinforcement members and extending from the side edges. The modular forms are positioned side by side so that one of the side edges of the modular forms is disposed in confronting, spaced-apart relation to a corresponding side edge of the other modular form. A molding plate for forming connecting surfaces is disposed between the confronting side edges of the modular forms. The connecting plates extending from the confronting side edges of the modular forms are then integrally connected to one another with the molding plate interposed therebetween. A construction material, such as concrete, is then poured into the modular forms and allowed to cure. The molding forms and the molding plate are then removed to form precast modular units having c
Adams & Wilks
Cohen Curtis A.
Stodola Daniel P.
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