SYSTEM AND METHOD OF FABRICATING A REINFORCED STRUCTURAL MEMBER
20250270829 ยท 2025-08-28
Inventors
Cpc classification
E04G21/02
FIXED CONSTRUCTIONS
International classification
E04G15/06
FIXED CONSTRUCTIONS
E04G21/02
FIXED CONSTRUCTIONS
Abstract
A structural member optimized to resist lateral forces, as well as systems and methods of fabricating and implementing same, are disclosed. In some implementations, a modular framework erected at a work site may support forms used for the fabrication of reinforced concrete or masonry structural members which do not have uniform cross-sectional thickness. The modular nature of the framework allows a construction crew to arrange the forms quickly and precisely on site, and the varying cross-sectional thickness of the structural member and positioning of reinforcing elements economize on materials usage while simultaneously increasing the structural member's resistance to lateral loading.
Claims
1. A structural member comprising: a first surface oriented to be substantially vertical, having a first height, and positioned to be exposed to an exterior side of a building; a second surface oriented to be substantially vertical, having a second height equal to the first height, and positioned substantially parallel to and in a spaced-apart relationship with the first surface, the spaced-apart relationship defining a substantially uniform baseline thickness of the structural member; a recessed region formed in a portion of the second surface and extending toward the first surface, the recessed region having a recess height that is less than the second height, a recess width that spans a horizontal distance of the second surface, and a recess depth from the second surface that is less than the baseline thickness of the structural member; wherein the recessed region defines an effective thickness of the structural member that is equal to a difference between the baseline thickness and the recess depth; and a reinforcing element intermediate the first surface and the second surface; wherein the reinforcing element is disposed intermediate the recessed region and the first surface, supports a portion of the structural member having the effective thickness, and is selectively positioned relative to the first surface such that a resistance to a given bending moment for the structural member as a whole is optimized.
2. The structural member of claim 1 wherein a material used for the structural member and defining the first surface and the second surface is concrete.
3. The structural member of claim 2 wherein the reinforcing element comprises a steel bar.
4. The structural member of claim 3 wherein the reinforcing element comprises a lattice of interconnected steel bars.
5. The structural member of claim 2 wherein the reinforcing element comprises a web structure.
6. The structural member of claim 5 wherein the web structure comprises a steel mesh.
7. The structural member of claim 5 wherein the web structure comprises a fibrous material.
8. The structural member of claim 2 wherein the recessed region is symmetrical in planar cross-section.
9. The structural member of claim 8 wherein the recessed region is rectangular in planar cross-section.
10. The structural member of claim 8 wherein the recessed region is trapezoidal in planar cross-section.
11. The structural member of claim 8 wherein the recessed region is curved in planar cross-section.
12. A method employing a modular framework system to facilitate fabrication of a structural member, the method comprising: securing an elongate base plate to a foundation operative to support the structural member, the securing comprising selectively attaching the elongate base plate to the foundation in an orientation substantially perpendicular to a longitudinal axis of a footprint of the structural member; attaching a column to a portion of the elongate base plate proximate to the footprint of the structural member and bracing the column in a substantially vertical orientation using a brace member attached to a portion of the elongate base plate distal to the footprint of the structural member, the column having a height selected to accommodate a selected height of the structural member; attaching a top support to the column opposite the elongate base plate and securing the top support in an orientation substantially parallel to a direction of the elongate base plate; selectively attaching a rail assembly to the top support in a substantially horizontal orientation and substantially parallel to the longitudinal axis of the footprint of the structural member; selectively suspending an interior form element from the rail assembly to define an interior surface of the structural member; selectively suspending an exterior form element from the rail assembly a distance from the interior form element to define an exterior surface of the structural member, the distance between the interior form element and the exterior form element defining a baseline thickness of the structural member; optionally selectively suspending an opening form element to define an opening, in which no structural material will be present, in the structural member, the optionally selectively suspending comprising selectively attaching the opening form element to at least one of the interior form element or the exterior form element; selectively suspending a reinforcing element from the rail assembly intermediate the interior form element and the exterior form element and positioning the reinforcing element in a position relative to the exterior form element to support the structural member against a bending moment; and depositing a slurry of construction material in a cavity between the interior form element and the exterior form element to form the structural member having the selected height.
13. The method of claim 12 wherein the selectively suspending an interior form element comprises suspending a recess element, having a recess depth from the interior surface of the structural member, that creates a recessed region having an effective thickness that is less than the baseline thickness of the structural member when the slurry is deposited in the cavity.
14. The method of claim 13 wherein the recess element is rectangular in planar cross-section.
15. The method of claim 13 wherein the recess element is trapezoidal in planar cross-section.
16. The method of claim 13 wherein the recess element is curved in planar cross-section.
17. The method of claim 13 wherein the selectively suspending a reinforcing element comprises positioning the reinforcing element proximate to the external form element such that the reinforcing element is entirely encased within an area of the structural element having the effective thickness.
18. The method of claim 12 wherein the depositing a slurry comprises depositing concrete in the cavity.
19. The method of claim 18 further comprising utilizing a trolley that translates on the rail assembly along the longitudinal axis of the footprint of the structural member to deposit the concrete in the cavity.
20. A modular framework system to facilitate fabrication of a structural member, the system comprising: an elongate base plate selectively attached to a foundation, which is operative to support the structural member, in an orientation substantially perpendicular to a longitudinal axis of a footprint of the structural member; a column attached to a portion of the elongate base plate proximate to the footprint of the structural member and having a height selected to accommodate a selected height of the structural member; a brace member attached to the column at a location above the foundation and below the height of the structural member and to a portion of the elongate base plate distal to the footprint of the structural member such that the brace member braces the column in a substantially vertical orientation during use; a top support attached to the column opposite the elongate base plate in an orientation substantially parallel to a direction of the elongate base plate; a rail assembly attached to the top support in a substantially horizontal orientation and substantially parallel to the longitudinal axis of the structural member; an interior form element selectively suspended from the rail assembly and defining an interior surface of the structural member; an exterior form element selectively suspended from the rail assembly a distance from the interior form element to define an exterior surface of the structural member, the distance between the interior form element and the exterior form element creating a cavity that defines a baseline thickness of the structural member; an opening form element optionally selectively suspended from at least one of the interior form element or the exterior form element to define an opening, in which no structural material will be present, in the structural member; and a reinforcing element selectively suspended from the rail assembly intermediate the interior form element and the exterior form element and positioned relative to the exterior form element to support the structural member against a bending moment.
21. The system of claim 20 wherein the interior form element comprises a recess element, having a recess depth from the interior surface of the structural member, that creates a recessed region having an effective thickness that is less than the baseline thickness of the structural member when a slurry is deposited in the cavity.
22. The system of claim 21 wherein the recessed region is symmetrical in planar cross-section.
23. The system of claim 22 wherein the recessed region is rectangular in planar cross-section.
24. The system of claim 22 wherein the recessed region is trapezoidal in planar cross-section.
25. The system of claim 22 wherein the recessed region is curved in planar cross-section.
Description
DESCRIPTION OF THE DRAWING FIGURES
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
DETAILED DESCRIPTION
[0034] Certain aspects and features of the disclosed subject matter may be further understood with reference to the following description and the appended drawing figures. In operation, a system and method of fabricating a reinforced structural member may have utility in connection with various construction projects for buildings, dwellings, and other enclosures. Specifically, the present disclosure provides for construction systems and methodologies that may generally make use of conventional hardware and tools that are familiar to construction contractors and work crews, but do so in a manner that is specifically designed to conquer some of the challenges (that have heretofore been unaddressed) associated with typical construction project practicalities.
[0035] The following detailed description and the appended drawing figures describe and illustrate some implementations of a system and method for the purpose of enabling one of ordinary skill in the relevant art to make and use these implementations. As such, the detailed description and drawing figures are purely illustrative in nature and are in no way intended to limit the scope of the disclosure in any manner. It should also be understood that the drawing figures are not necessarily to scale and that in certain instances, details which are not necessary for an understanding of the disclosure, such as details of material hardness or strength and curing times or other parameters, may have been omitted from the drawing figures or the written description for clarity. As noted above, in the accompanying drawing figures, like reference numerals are used to represent like components throughout, unless otherwise noted.
[0036] The features of some implementations are described below with reference to illustrations of methods, systems, and structural members, per se, according to the disclosed implementations. As noted above, it will be understood that individual blocks or structural components depicted in the drawing figures, as well as certain combinations of blocks depicted in the drawing figures, may be facilitated by computer program instructions, hardware (electrical, electro-mechanical, or mechanical) devices, or a combination of both, used in connection with automating aspects of the method, such as, for instance, design, manufacture, placement, and alignment of physical components of the system. Some computer program instructions may be provided to or from a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce or enable a particular machine, such that the instructions, which are executed via the processor of the computer or other programmable data processing apparatus, implement the functions specified in the block or blocks, either individually or in combination. Such computer systems may be used to design, arrange, and/or fabricate the physical components depicted in the drawing figures or their equivalents. This will be especially apparent in the discussion of the placement of physical components which embody the system or parts thereof.
[0037] In that regard, it is noted that aspects of the present system and method may be designed, tested, refined, modified, or implemented with the assistance of or in connection with one or more computing devices, including one or more servers, one or more client terminals, including computer terminals, a combination thereof, or on or facilitated by any of myriad computing devices currently known in the art, including without limitation, personal computers, laptops, notebook or tablet computers, touch pads, multi-touch devices, smart phones, personal digital assistants, other multi-function devices, stand-alone kiosks, etc. These, or any combination of these, may have utility in designing the mechanical components of the systems illustrated in the drawing figures, as well as in computing forces, stresses, strains, and expected life spans of given structural members under a given set of assumptions and performance requirements.
[0038] Turning now to the drawing figures,
[0039] The design of any wall generally requires creating a structural member having adequate resistance to forces and vectors (where a vector comprises a force component and a directionality component). Particularly in the case of an exterior wall (i.e., one having an exterior surface exposed to an exterior of a structure, and thus being exposed to wind and other environmental elements), adequate resistance in this context generally requires simultaneous support in opposition of both vertical loads (i.e., gravity and uplift roof loads) as well as horizontal or lateral loads (e.g., wind loads). Since gravity loads (particularly in the context of residential construction projects) are typically very small relative to the maximum compression loads that even conventional masonry or concrete structures can support, it is instead the lateral loads that are expected to be exerted on a particular wall segment which generally control the specifications, design, and construction of that particular wall segment. As a result, many construction engineers and crews design and build the wall as (in essence) a vertically oriented beam that is subjected to wind load vectors which act generally perpendicular to the wall's plane in two principal horizontal directions, depending on the wind direction, namely: inward oriented vectors (e.g., when the exterior surface of the wall is on the windward side of the structure, and the wind is incident on the exterior surface), or outward oriented vectors (e.g., when the exterior surface of the wall is on the leeward side of the structure, and the lateral forces experienced by the wall are communicated through the structure, which is typically referred to as internal pressure, and when wind shedding off a building causes suction or a partial vacuum, creating an outwardly directed vector on an exterior surface). Specifically, the wall must be designed to act as a beam capable of resisting forces applied from either direction, which is exactly how the prior art wall section (reference numeral 100) of
[0040] As depicted in the drawing figures, prior art wall 100 has a top 101 and a bottom 102, the distance between top 101 and bottom 102 generally defining a height of wall 100. It will be appreciated that top 101 typically supports a floor joist (or a plurality of joists) serving as a base for an additional story, a roof sill or plurality of rafters to support a roof, or other structural members as is generally known in the art, and that bottom 102 is either supported by one or more floor joists, support beams, or a foundation (or a foundational slab), for example, all of which would be configured and operative to carry the weight of wall 100 and the other structural components supported by wall 100. These ancillary elements are omitted from
[0041] Wall 100 generally has an interior surface 110 (on an interior, protected, or leeward side) and an exterior surface 130 (on an exposed, weather, or windward side). These surfaces 110 and 130 are usually substantially parallel to each other at a uniform distance apart, which distance along transverse axis 172 defines a thickness (T in
[0042] Lateral wind forces (represented by the block arrows in
[0043] As noted above, such traditional placement of reinforcing system 190 relative to thickness T of wall 100 is generally due to the fact that wall 100 is intended to be configured and operative to resist lateral forces in two directions (i.e., both inward vectors and outward vectors); placing reinforcing system 190 at a center (along transverse axis 172) of wall 100 such that d=T/2 establishes a substantially equal reinforcing functionality for both wind load vector directions. However, by placing the mass of components 191 and 192 of reinforcing system 190 midway between interior surface 110 and exterior surface 130, by design, when a wind load vector is in the inward direction (e.g., from right to left in
[0044] This is what is referred to as a wasteful dilemma of current wall design and construction; purposefully and by design, the d value (which is a direct representation of a moment resistance capacity) is based upon only one half of thickness T of a conventional wall 100. Even the building code promulgated by the American Concrete Institute (specifically, ACI-318), which is the preeminent code for reinforced concrete construction in the United States, assumes uniform wall cross-sectional area in all relevant code provisions. The same is true for reinforced masonry construction design. Not only is the moment resistance capability of a uniformly thick wall having a reinforcing structure at its transverse midpoint limited considerably because the d value is limited to only half of the wall's thickness, but also, those of skill in the art will appreciate that almost half of the concrete or masonry utilized for construction of such walls is structurally non-functioning (at least vis--vis lateral loading), depending upon the wind (or other source of lateral load vector) direction.
[0045] As set forth in detail below, aspects of the present disclosure address the forgoing limitations inherent in prior art wall 100, providing both a wall that has novel geometric characteristics to minimize wasted structural material and an efficient mechanical system and methodology to create such a wall. The walls, systems, and methods illustrated and described herein were developed to optimize use of construction materials that are necessary to achieve the wall's function and desired or required structural characteristics; additionally, the systems and methods to create such a wall were developed to minimize human labor and manhours required while still ensuring quality construction results. In many implementations, the use of interchangeable parts or components that are reusable and portable facilitates construction processes that are efficient and repeatable, such that a construction crew may consistently create reinforced walls or other structures having predictable performance characteristics with minimal effort as compared to conventional construction methodologies.
[0046] In that regard,
[0047] During construction of structural member 200, portions of a reinforcing system 700 may be offset from a centerline between interior surface 110 and exterior surface 130 and biased towards exterior surface 130. As set forth in more detail below, a wall plane reinforcement element may be embodied in or comprise rebar, other metal structures, wire or steel mesh, or fabric or other fibrous materials such as are generally known in the art (reference numeral 791). In some implementations, wall reinforcement element 791 is disposed intermediate recess surface 297 (i.e., at recessed region 299) and exterior surface 130, supports a portion of structural member 200 having effective thickness T.sub.e, and is selectively positioned relative to exterior surface 130 such that a resistance to a given bending moment for structural member 200 as a whole is optimized for the amount of construction materials used. In some implementations, an additional columnar or post component (post reinforcement element, reference numeral 793) of reinforcing system 700 may be deployed at areas of wall 200 which do not include recess region 299; such a post reinforcement element 793 is discussed in more depth below with specific reference to
[0048] Those of skill in the art will appreciate that the description of
[0049] Turning now to systems and methods of constructing such a wall or other building component, it is noted that
[0050] During construction of reinforced structural member 200, a base plate 220 and, optionally, a brace shoe 240 (see
[0051] In that regard, base plate 220, brace shoe 240, or both, may be constructed of metal (such as steel, stainless steel, aluminum, titanium, bronze or other alloys, and the like), ceramic, glass, fiberglass, carbon composites, or other materials generally known in the construction arts. The present disclosure is not intended to be limited by the particular materials used for base plate 220 or brace shoe 240, though it is noted that the specific dimensions of these components may vary as a function of the materials employed, and that the materials should be selected to have strength, weight, and corrosion resistance characteristics that are suitable for an intended use and an expected life-span of the components.
[0052] As illustrated, base plate 220 may be elongate and comprise a generally horizontal plate portion 227 which may be selectively attached or secured to foundation 290 in an orientation that is substantially perpendicular to a longitudinal axis of reinforced structural member 200 (i.e., perpendicular to longitudinal axis 271 as best depicted in
[0053] Similarly, brace shoe 240 may be square, circular, polygonal, or elongate (though appreciably shorter than elongate base plate 220) and comprise a generally horizontal plate portion 247, a brace member support flange 242 disposed at or near an end that is positioned proximal to column support bracket 221 and, optionally, an aperture 249 to facilitate securing brace shoe 240 to foundation 290 as set forth above. In use, brace shoe 240 may be selectively attached or secured to foundation 290 in an orientation that aligns brace member support flange 242 substantially parallel to longitudinal axis 271 (as best depicted in
[0054] By way of background, a wall such as reinforced structural member 200 may be conceptualized fundamentally as the connection of four corner points located in three-dimensional space by a rigid plane. Given four corner points located precisely in space, then a rigid plane having corners located exactly at these four points will establish a surface of the structural member (such as 200). Mirror this surface about a longitudinal axis (such as 271), and the other, opposite surface of the structural member 200 is established. From the perspective of a construction company or site crew, one engineering objective is to be able to accomplish this with precision and efficiency, with minimal time and effort expended by skilled laborers.
[0055] With this context, it will be appreciated that base plate 220 serves two functions: two adjacent base plates 220 may be used as a rigid point of connection as set forth in detail below to establish two out of the four corner points (the two bottom points) of the surface of the structural member 200; and each base plate 220 further creates a rigid connection point for lateral bracing of vertical components of a construction system framework to be described below. This is done with a single part (horizontal plate portion 227) having two fasteners (column support bracket 221 and brace member support flange 222) selectively connected to the supporting foundation 290 (such as a concrete slab, floor joist, sill, beam, or the like). Complementing operation of base plate 220 in use, brace shoe 240 may generally create a rigid connection point for lateral bracing of vertical components in the opposite principal direction (i.e., substantially perpendicular) from base plate 220. In some implementations, one or more brace shoes 240 may be optimally located at or near a building's or other structure's primary outer corners.
[0056] As noted above, specific materials and dimensions of base plate 220 and brace shoe 240 may vary as application-specific design choices, but it will be appreciated that they may be so designed and implemented safely to support all forces and vectors to which they are intended to be subjected throughout a given application (i.e., a given construction process).
[0057]
[0058] As with base plate 220 and brace shoe 240, column 320 and bracing member 340 may be constructed of any of various suitable metals, ceramic, glass, fiberglass, carbon composites, or other materials generally known in the art, and are not limited to any particular material, though it will be appreciated that the specific dimensions (including diameter, thickness, wall thickness in the case of hollow embodiments, etc.) of these components may vary as a function of the materials selected and their respective strength and ductility characteristics.
[0059] As best illustrated in
[0060] To accommodate lateral support during use, column 320 may also include a brace member attachment element generally identified by reference numeral 350 in
[0061] Brace member 340 may comprise two structures (such as flanges, tabs, grooves, apertures or pre-drilled holes, snap-together fasteners, or the like) each of which is disposed at a respective end of brace member 340, and which are respectively configured and operative to cooperate with or otherwise to engage either brace member attachment element 350 or brace member support flanges 222 and 242, substantially as illustrated in
[0062] It is noted that in the illustrated implementation, column 320 is designed to mate with column support bracket 221 using a slip-fit engagement, enabling a quick and easy installation requiring only minutes of labor. In this circumstance, it may be desirable to include apertures or pre-drilled holes in the cooperating structures (of one or both of column 320 and column support bracket 221) to accommodate fasteners (such as bolts or set screws) to ensure proper placement and orientation of column 320, for instance, to ensure that one or more brace member attachment elements 350 are properly aligned to couple with one or more brace members 340. In the case of a column 320 having a square or rectangular planar cross-section and a column support bracket 221 having a circular planar cross-section (as in the illustrated arrangement), such fasteners may have utility in preventing a work crew from installing column 320 on column support bracket 221 in any orientation or alignment other than as intended.
[0063] When one or more brace members 340 are installed as illustrated (and their respective lengths optionally adjusted as set forth above), column 320 may then be supported substantially plumb relative to the supporting surface (such as foundation 290), even in the event of minor elevation changes or imperfections in the supporting surface (an inevitable outcome). This entire process may be accomplished in a matter of minutes for each column 320 to be deployed. After properly braced and plumbed, the top portion of two adjacent columns 320 may then be used as set forth in detail below to establish the remaining two points (i.e., the top two points) defining principal corners of a portion of reinforced structural member 200 as described above.
[0064] In some implementations, column 320 may also comprise a top support attachment point 371 and a lower rail attachment point 372. These attachment points 371 and 372 may be constructed to engage with cooperating structures on a top support structure and a lower rail assembly described below. Attachment points 371 and 372 may generally be embodied in or comprise apertures such as pre-drilled holes or slots, for example, or brackets, clips, or flanges integrated with structure of column 320, depending upon the structural characteristics and implementation details of the top support structure and the lower rail assembly, respectively, with which they are designed to couple, the materials from which column 320 is constructed and its planar cross-section, or a combination of these and a variety of other factors. The use and purpose of these attachment points 371 and 372 will become apparent in the discussion of the other system framework components set forth below.
[0065] As noted above with reference to other physical elements of a system for fabricating a reinforced structural member, the specific materials and dimensions of column 320 and brace member 340 may vary as application-specific design choices, but it will be appreciated that they may be so designed and implemented safely to support all forces and vectors to which they are intended to be subjected throughout a given application (i.e., a given construction process).
[0066]
[0067] The primary purpose of top support structure 400 is to position horizontal portion 420 (and in some instances, more than one such horizontal portion, as indicated at reference numerals 421 and 422 in
[0068] In the illustrated versions of
[0069] As noted generally above,
[0070] As noted above with reference to other physical elements of a system for fabricating a reinforced structural member, the specific materials (such as, for example, steel, other metals or alloys, glass or ceramics, fiber or other composites, and the like) and dimensions of top support structure 400 (specifically vertical member 470 and cantilevered supports 421 and 422) may vary as application-specific design choices, but it will be appreciated that they may be so designed and implemented safely to support all forces and vectors to which they are intended to be subjected throughout a given application (i.e., a given construction process) without unwanted deflection or warping.
[0071]
[0072] In use, rail assembly 500 may be configured and operative to suspend the form structures and reinforcing system 700 (described below) that may be used to define reinforced structural member 200 to be fabricated; it may also support a movable dispensing component that may translate linearly along rail assembly 500 selectively to deposit construction materials (e.g., a material slurry) serving as the composition of reinforced structural member 200. Where structural members 200 meet at a corner of a structure (e.g., at a right angle or otherwise), one rail assembly 500 for one structural member 200 may be positioned adjacent to and abutting another rail assembly 500 for the other structural member 200 as best depicted in
[0073] As best illustrated in
[0074] It will also be appreciated that the number and spacing of cross members 550 themselves may vary by application, but in some instances, it may be desirable to keep the number and spacing uniform for a given longitudinal span; in this manner, any given rail assembly 500 may be interchangeable with any other on a job site, minimizing effort and risk of mistake on the part of a job site work crew. Top chords 521 and 522 may include apertures, pre-drilled holes, or alignment indicia (reference numerals 531 and 532, respectively) to facilitate proper engagement with, and orientation with respect to, cooperating elements or pre-drilled holes at appropriate attachment sites (see reference numerals 423 and 424 in
[0075] In the illustrated implementation, top chords 521 and 522 may be securely attached (at points 531 and 532, respectively) to cantilevered supports 421 and 422 (at points 423 or 424, as applicable), for example, with bolts, screws, set screws, wing nuts, or other fasteners that are generally well known in the art, though other options are contemplated. In some instances, hardware employed to make this mechanical connection may be selected to have a low profile (e.g., in the side view of
[0076] In use, rail assembly 500 may be constructed as a three-dimensional space frame or box truss that is structurally sized, dimensioned, and constructed simultaneously to resist all superimposed vertical gravity loads and lateral loads while exhibiting negligible deflection in both principal directions (i.e., along longitudinal axis 271 and transverse axis 272), as well as negligible twisting or torsional deformation. Accordingly, the number, spacing, and thickness of cross members 550 per unit length in the longitudinal direction, as well as the depth and profile of taper 570, may be selected as a function of the overall length of rail assembly 500 and the weight of the construction components to be supported, among other factors such as the material used and its structural characteristics and performance parameters (such as hardness, rigidity, temperature tolerances, and the like).
[0077] Those of skill in the art will appreciate that rail assembly 500 configured and constructed as set forth herein represents an innovative support platform for both suspending wall forms (such as at bottom chords of the box truss represented by hanging chords 551 and 552) and a track system (such as at top chords of the box truss represented by top chords 521 and 522) for additional equipment such as a deposition hopper or trolley to deposit construction materials as set forth below with reference to
[0078] As noted above with reference to other physical elements of a system for fabricating a reinforced structural member, the specific materials (such as, for example, steel, other metals or alloys, glass or ceramics, fiber or other composites, and the like) and dimensions of rail assembly 500 (as well as its constituent components) may vary as application-specific design choices, but it will be appreciated that they may be so designed and implemented safely to support all forces and vectors to which they are intended to be subjected throughout a given application (i.e., a given construction process) without unwanted deflection or twisting.
[0079]
[0080] Initially, it is noted that an interior wall form 600 may generally be embodied in or comprise a conventional wall form such as is typically employed in the construction arts. Those of skill in the art will appreciate that the utility of the disclosed systems and methods is not intended to be limited by the nature, size, shape, and characteristics of interior wall form 600.
[0081] With that in mind, however, it is also noted that, in some implementations, form 600 may be constructed with a frame fabricated of high strength structural aluminum (or other metal or alloy) or composite material and having framing components or support structures that are precisely placed to maximize strength, minimize deflections, and reduce weight of overall form 600, facilitating installation of same by suspension from appropriate elements of rail assembly 500 as set forth above. In some implementations of such a reinforced or braced form 600, a primary surface or skin may be fabricated of ultra-high strength, lightweight fiberglass (or other composite material) having a T beam vertical cross-sectional profile (in which the bottom of the T, the web of the beam, extends away from the exterior surface of the form as a ridge or elongate protrusion) to provide rigidity and lateral support. This skin may be attached to the high strength metal frame defining the overall shape of form 600 using techniques that are generally known in the art.
[0082] In practice, a number of vertically oriented, elongate T beams may be strategically placed to run at horizontal intervals which may be uniform or varied, for instance, as a function of the location and spacing of cross members or other framing components that support the skin, and perhaps relative to the overall height of the structural member 200 to be constructed, expected load distribution, the material properties of the materials used for form 600, or a combination of these and a variety of other factors. The resulting profile may create a structural skin for form 600 that may exhibit a high moment of inertia (resistance to bending) due to the protruding miniature beam webs and the ultra-high strength fiberglass or other material employed. For example, some fiberglass or other composites may exhibit resistance to tensile loads of up to or even exceeding 55,000 pounds per square inch (stronger than some commonly used structural steel compositions). Such a construction approach may allow for a lightweight, yet strong and deformation resistant, panel skin for form 600, and in some cases, the use of a T beam strategy for the skin profile may compensate for the inherently low modulus of elasticity (resistance to strain) of fiberglass or other lightweight composite materials used in construction of form 600. When the composite skin is applied or otherwise attached to the frame cross members, the resulting form 600 may be configured and so dimensioned such that each frame component and the overall skin surface is structurally loaded to capacity and located to create substantially uniform and negligible skin deflection (resulting in a uniformly fabricated structural member 200), even though form 600 may be required to withstand a triangular load distribution (up to about 1,400 pounds per square foot for a 10 foot high wall, perhaps higher for a higher wall) when wet construction material slurry is poured.
[0083] Returning now to the drawing figures,
[0084]
[0085] Recess form 601 is illustrated at having a baseline surface 611 to define an interior surface, and thereby the baseline thickness, of reinforced structural member 200, as well as a recess element 620 that slopes to a recess surface 621, which defines a recess depth (reference numeral 298 in
[0086] It is noted that a given recessed region 299 (having a recess depth 298) may span an horizontal portion of recess form 601 that is less than the overall horizontal width (i.e., along longitudinal axis 271) of recess form 601 itself. By abutting two or more such recess forms 601 next to each other (
[0087] The shape of recess form 601, and in particular, the shape and contours of recess element 620, are susceptible of numerous variations. For example, recess element 620 may be oval, oblong, rounded, square, or rectangular in plan, cross-section, or both; alternatively, in the trapezoidal implementation illustrated, the slopes or angles may vary as desired for a particular application, taking care to adjust locations of beam webs 657, if applicable, as necessary or desired to ensure proper engagement with cross beams 630 of form frame 650. As another alternative, the vertical height, horizontal span, or both, of a given recess element 620 may be modified as a function of specific design constraints or performance requirements for the reinforced structural member 200 to be fabricated. For example, a single recess form 601 may comprise more than one recess element 620 distributed horizontally along longitudinal axis 271 in some implementations; similarly, such a single recess form 601 may comprise more than one such recess element 620 distributed vertically.
[0088]
[0089] Also in connection with resisting forces during use, it is noted that
[0090] In some instances when rail assembly 670 may be longer or shorter than a span between adjacent columns 320 (at corners of structural member 200, for instance), such a generic lower rail assembly 670 may be used to join two or more adjacent exterior forms 800 (described below) and may be operative to prevent relative movement of these exterior forms 800 during use, either in addition to, or in lieu of a lower rail assembly 670 as implemented in
[0091] Upon installation of lower rail assembly 670 and suspension of recess form 601 from interior hanging chord 551, a lower portion of recess form 601 may be attached, secured, or otherwise simply made to contact or abut support clips 673 disposed longitudinally along longitudinal axis 271 at various locations along lower rail 671. The locations of support clips 673 may be selectively adjustable, for example, such that support clips 673 may be selectively relocated depending upon a structure of recess form 601 (or any other generic form 600) that is to be supported. Additionally or alternatively, recess form 601 (or others described below) may be fabricated with cooperating structures to mate specifically with support clips 673 on a universal or form agnostic lower rail assembly 670. In some instances, recess form 601 may be rigidly attached (such as by bolts, screws, press-fit couplings, etc.) to support clips 673, though this is not strictly necessary. In some implementations, support clips 673 may be deployed at a point at which two adjacent forms (such as recess form 601) abut each other (such as at bumper 640), and may be configured and operative to prevent relative movement between the two abutting forms.
[0092] It is noted that any number of conventional mechanisms may be used to suspend recess form 601 (or any generic form 600) from interior hanging chord 551, and that the present disclosure is not intended to be limited by any particular mechanism, strategy, or arrangement of elements. By way of example, c-hooks, s-hooks, wires, cables, and the like may all be suitable; the type of hanging hardware, as well as its construction, materials, coatings, and the like, may be selected as a function of the construction of the forms 600 themselves (as well as their weight and the distribution of that weight), corrosion resistance, disposability or reusability, and a variety of other factors. In some cases, a simple bolt fastener may be used to suspend a form 600 from interior hanging chord 551.
[0093] In particular, the illustrated structural arrangements depict a reciprocating throw-pin 695 mechanism which may have utility in engaging recess form 601 (or any other form described herein) with interior hanging chord 551 (or from exterior hanging chord 552, as the case may be). In this arrangement, throw-pin 695 is capable of linear translation along an interior of vertical member 652, and may be made to project vertically through an aperture (reference numeral 643) at the top of form frame 650; a detent mechanism (such as a groove and flange arrangement, for example) may be employed to maintain throw-pin 695 in this extended position during use. As best seen in
[0094] In addition to the trapezoidal shape of recess form 601, a variety of other shapes and sizes for interior form 600 are contemplated. Corner forms (e.g., for use where two adjacent structural members meet at an acute, right, or obtuse angle), flat forms (e.g., for use at door and window locations, or in locations where no recess region 299 is desired), beam forms (e.g., for use at overhead beam locations at windows and doors), and sill forms (e.g., for use below window locations or at door thresholds) may all be used. As with recess form 601, all of these additional form shapes and sizes may be pre-fabricated for efficient suspension from rail assembly 500 as set forth above or for support by another form 600 as set forth below. In some cases, simple bolt fasteners or wing nuts may be sufficient for hanging forms 600, though other integrated hardware may be employed as desired.
[0095] In that regard,
[0096] Addressing general use of additional shapes of a form 600, it is noted that
[0097] In general, it will be appreciated that flat beam form 602 and sill form 604 may be selectively employed to support or otherwise to cooperate with dedicated inserts (described below) which define two different types of openings: a peninsula opening which creates a doorway (
[0098] Upon installation of any beam forms 602, any sill forms 604, or both, as desired or applicable, and after vertical placement adjustments, as desired or necessary (and as applicable), a finished rough opening defined by inserts supported by the forms may be created to be dimensionally precise in both principal directions (vertically and horizontally), angularly precise at every corner, and geometrically accurate in an elevation perspective. With the framework erected in accordance with the discussion above and the top rail assembly 500 in place to suspend suitably constructed forms 600, each insert defining an opening for a given structural member or wall may installed in a manner of minutes, regardless of opening size or location, without reliance upon surveyors, expensive (and perhaps fragile) equipment, and skilled labor.
[0099] It will be appreciated that forms 600 may be implemented to accommodate large window and door openings by placing dedicated panel forms at each side jamb, and a large opening beam at the top horizontal header. Application specific forms 600 may facilitate creation of large openings (sliding glass doors, large picture windows, garage doors, etc.), arched, circular, or irregularly shaped openings, and the like, with repeatable accuracy and mechanical efficiency substantially as set forth in more detail below.
[0100] In that regard,
[0101] It will be appreciated that attachment of beam insert 609, frame elements 608 (if applicable), and opening insert 607, either to each other or to interior forms 600, may be accomplished as noted above, i.e., with screws, bolts, clips, tie-rods, clamps, or other appropriately sized and dimensioned fastening members generally known in the art. It is further noted that the construction of beam insert 609, frame element 608, and opening insert 607 may be similar to the frame 650 and skin 659 of forms 600 described above, though simplified or conventional approaches may also be used. The present disclosure is not intended to be limited by any specific construction or framing techniques used for beam insert 609, frame element 608, or opening insert 607, or by any particular manner in which the various system components are mechanically coupled (though it is noted that any hardware may be selected from materials having appropriate strength, ductility, and corrosion resistance characteristics that are necessary or desirable for a particular use, expected working environment, and longevity considerations).
[0102] Upon completion of the installation of the various system components, including appropriate interior forms 600 which define straight wall portions, recessed wall portions, and corners, as well as beam inserts 609, opening inserts 607, 608, or both, as applicable, which define doors, windows, and the like (in accordance with a particular building's blueprint specifications), an entire interior face plane of that building's walls is defined.
[0103] As noted above with reference to other physical elements of a system for fabricating a reinforced structural member 200, the specific materials (such as, for example, aluminum, steel, other metals or alloys, glass or ceramics, fiberglass or other composites, and the like) and dimensions of the forms illustrated in
[0104]
[0105] Specifically, in one implementation, a reinforcement assembly 770 may generally comprise an outer hanger 771, a center hanger 772, and an inner hanger 773. As best illustrated in
[0106] The location of these attachments points (columns 581 through 583) on cross member 550 ensures that center hanger 772, once coupled with center column 582 of attachment points, will always hang directly over a center of the baseline thickness of structural member 200 (i.e., a lateral distance T/2 from interior baseline surface 611); thus, a single beam reinforcement element 792 supported by center hanger 772 will always be at the lateral center of a beam structure having the full baseline thickness T. Depending upon the viewpoint of top rail assembly 500, either the left column 583 of attachment points (the left in
[0107] Hangers 771 through 773 may be attached to cross member 550 via any conventional attaching hardware generally known in the art. Press-fit couplings, set screws, bolts, rivets, and the like are all contemplated. In some instances, attachment points on cross member 550 may be pre-drilled holes to accommodate screws or bolts, for example, or corresponding protuberances extending from hangers 771 through 773. Alternatively, hangers 771 through 773 may incorporate pre-drilled holes to engaged nubs or other protrusions of respective columns 581 through 583 at attachment points on cross member 550. In that regard, hangers 771 through 773 may be fabricated using disposable or recyclable plastic, rubber, silicon, or other material, though metals, alloys, fibers, and composites are also contemplated. The present disclosure is not intended to be limited by the nature of the materials used for fabricating hangers 771 through 773, or the manner in which these components are attached to, coupled with, or suspended from attachment points on cross member 550, though it is noted that the foregoing lateral placement of outer hanger 771 and inner hanger 773 relative to center hanger 772 may be of importance in many applications.
[0108] Specifically, selective placement of outer hanger 771 and inner hanger 773 along transverse axis 272 will influence the respective lateral positions of wall plane reinforcement element 791 and any beam reinforcement element 792 relative to the overall structure of reinforced structural member 200; this is particularly true when two beam reinforcement elements 792 are supported, respectively, by inner hanger 773 and outer hanger 771, rather than in the case of a single beam reinforcement element being supported by center hanger 772.
[0109] By way of additional background, it is noted that a wall's (or other structural member's) reinforcing system may be one of its most structurally important components (depending upon the application), and is typically one of the most expensive components, taking into consideration both material costs as well as labor costs associated with its installation. Accordingly, deliberate control over the amount of materials (such as steel) employed in a reinforcing system (such as reinforcing system 700), and carefully minimizing labor time during installation of same may benefit overall construction economies. Hanging reinforcement system 700 from top rail assembly 500 as indicated in
Wall Plane Reinforcement:
[0110] In typical concrete wall construction, horizontal and vertical steel bars (i.e., rebar) are placed and oriented, individually, and thereafter secured to each other using wire ties to create a steel lattice. Since each bar must be placed individually, and subsequently attached manually to a number of other bars that cross it, the process of creating this latticework arrangement is both labor intensive and prone to error and irregularities. This increases construction costs, because skilled labor is involvedand the process itself demands a lot of that skilled labor.
[0111] In a departure from conventional methodologies, on the other hand, wall plane reinforcement element 791 may eliminate rebar and wire ties altogether, replacing them with one or more pre-fabricated components. In some implementations, wall plane reinforcement element 791 may be embodied in or comprise a pre-fabricated welded wire fabric sheet, for example, though other options are contemplated. For example, wall plane reinforcement element 791 may be embodied in or comprise a pre-fabricated fiberglass or composite material mesh, sheet, or latticework; specifically, wall plane reinforcement element 791 need not be fabricated of steel or other metals, though metal reinforcement is popular in the industry and specified in some building codes and industry standards or guidelines. The specific construction, gauge, thickness, orientation, and pattern of metal or fabric sheet may vary by application or as a design choice, but in any event, wall plane reinforcement element 791 may be easier to manipulate and to install than conventional rebar and wire tie implementations.
[0112] For example, ACI requires that a wall must be reinforced with a certain percentage of steel (or other suitable metal or composite material) per area of concrete; in accordance with one such standard, the specified percentages are 1.2% vertical steel to concrete area and 2.0% horizontal steel to concrete area. In accordance with aspects of the systems and methods set forth herein, however, since the unique cross-sectional shape of structural member 200 includes recessed regions 299 having only about one half the concrete thickness of the baseline thickness, this steel area requirement specified by the applicable standard is reduced by about half. As a result, instead of bulky rebar that is cumbersome to handle and to install, pre-fabricated lightweight reinforcing steel mesh sheets (or other suitable reinforcing webbed or meshed materials) may be utilized to satisfy the applicable reinforcing requirements specified in the standard. Further, due to the fabrication system framework's top rail assembly 500, various components of reinforcing system 700 may be installed by hanging the reinforcing steel (such as wall plane reinforcement element 791) from cross members 550 with the use of inexpensive plastic support hangers (such as outer hanger 771). As noted above, hangers 771 through 773 may have connection stubs or other protuberances that are simply snap-fit or otherwise inserted quickly and efficiently into pre-drilled, precisely located holes in cross members 550, thereby ensuring that the various reinforcing elements 791 through 793 may be precisely located within an inner core of structural member 200. While other embodiments are contemplated for such hangers 771 through 773 (and the mechanical connections between them and the attachment points associated with cross member 550), it may be desirable to use inexpensive, disposable, or consumable hanger hardware for this limited purpose. Further, since the reinforcing sheet or lattice (e.g., wall plane reinforcement element 791) is suspended from above rather than supported at foundation 290, all proper ACI concrete coverage requirements are satisfied around the entire perimeter of reinforcement system 700, even at the bottom.
Beam Reinforcement:
[0113] In accordance with many applicable building codes or relevant industry standards, beams (i.e., portions of a structure above a fenestration such as a door or window) may be reinforced with the use of longitudinal bars and stirrups (if necessary for shear forces). However, given the subject matter disclosed herein, it will be appreciated that wall plane reinforcing concepts in reinforcing system 700 may be utilized for both flexural and shear support, thereby reducing the conventional beam bar reinforcing required to resist loads. In this case, beam steel may be installed by hanging longitudinal bars or other suitably modified wall plane reinforcement element 791 material from top rail assembly 500 (e.g., adjacent beam forms 602); this component is illustrated in
Column Reinforcement:
[0114] Columns may generally be reinforced with the use of vertical bars, posts, tubes, or other elongate structural members; such a post reinforcement element is illustrated abstractly at reference numeral 793 in
[0115] In some implementations, post reinforcement element 793 may be embedded into foundation 290, or otherwise rigidly affixed to it, as in conventional wall design and construction. Additionally or alternatively, post reinforcement element 793 may be suspended from the fabrication system framework's top rail assembly 500, for example, either from inner hanger 773 or center hanger 772, depending upon application. In instances where post reinforcement element 793 is integral with or otherwise rigidly attached or coupled to foundation 290 from below with conventional hardware, it may be desirable not to support it from above, such that the entire post reinforcement element 793 will be covered with construction material upon completion of the reinforced structural member 200.
[0116] Post reinforcement element 793 may be embodied in or comprise a solid cylinder, post, or bar, a hollow tube, or other elongate structural member, and may have an exterior surface that is smooth, roughed, grooved, or fluted, for example, to facilitate mechanical bonding with or adhesion to concrete or other materials used for the structure of structural member 200. It will be appreciated that post reinforcement element 793 may have any plan cross-sectional shape that is appropriate for a given application, and it may be installed by simply tying it to pre-installed dowels located at foundation 290, for instance, and to the wall/beam top bar or it may be hung from a hanger 773 or 772 as indicated above. Inexpensive, plastic spacers (of any selected geometry) may be installed at selected vertical locations of post reinforcement element 793 to ensure precise placement, and to ensure compliance with all ACI and applicable building code concrete coverage requirements.
[0117] In accordance with the foregoing mechanical framework, optimized structural design, and construction methodologies focused on efficiency, structural member 200 may be laid out and wall plane reinforcement elements 791, beam reinforcement elements 792, and post reinforcement elements 793 may be placed and installed to ensure code-compliant reinforcement in a precise, repeatable, and efficient manner, all while employing much less steel (or other reinforcing material) and much less labor than required by traditional construction methods fabricating conventional, inefficient structural members (reference numeral 100). Using the systems and methods disclosed herein, an entire span of a large horizontal wall run may be reinforced within a matter of minutes, using approximately one-third less reinforcing material than is normally required for conventional applications, while still producing a structurally superior installation.
[0118]
[0119] In some instances, conventional construction forms may be used for exterior form 800. Alternatively, an exterior form 800 such as flat form 801 may be constructed in the same manner, and of the same materials, as interior forms 600 described above in connection with
[0120] As noted above, the aforementioned skin 659 of flat form 801 generally comprises a baseline surface 811 to define an exterior surface, and thereby (and in cooperation with baseline surface 611 of an interior form 600) the baseline thickness T, of reinforced structural member 200. Flat form 801 may be so dimensioned to span an horizontal run substantially the same as that of an opposed interior form 600. As best illustrated in
[0121] Similar to
[0122] In addition to the full length flat form 801 (i.e., full length in this context is intended to mean that it spans an entire vertical height of structural member 200), a variety of other shapes and sizes for exterior form 800 are contemplated. Corner forms (e.g., for use where two adjacent structural members meet at an acute, right, or obtuse angle), beam forms (e.g., for use at overhead beam locations at windows and doors), and sill forms (e.g., for use below window locations and at door thresholds, if applicable) may all be used. As noted above in connection with interior forms 600, such complementary shapes and sizes of exterior form 800 may be pre-fabricated for efficient suspension from rail assembly 500, or from another form 800, as set forth above. In some cases, simple bolt fasteners or wing nuts may be sufficient for hanging forms 800, though other integrated hardware may be employed as desired and as set forth in detail above. Specifically, attachment hardware 841 and throw-pin 895 may be analogous to attachment hardware 641 and throw-pin 695 described above, and may be operative in a substantially similar manner, to support exterior forms 800 from hanging chord 552.
[0123] Addressing additional shapes of a form 800, it is noted that the forms 602 and 604 illustrated in
[0124] In addition to cross beams 830 that provide rigidity, flat form 801 may also include through-bores or slots (reference numeral 890) at locations opposite cooperating through-bores or slots in recess form 601 (reference numeral 690 in
[0125] Specifically, an external form 800 may be secured to an interior form 600 with the use of a tension tie assembly (reference numeral 880 in
[0126] In some implementations, a tension tie assembly 880 may generally comprise a sleeve 881 having a flange or a radial widening at each end. Such a flange or flute may prevent concrete or other construction material from entering the tube created by sleeve 881 (and from escaping through slot 690, 890) during use, and, when sleeve 881 is of a specific length (for instance, T), then such a flange or flair will also help to ensure that the reinforced structural member 200 is always the correct thickness (i.e., a flanged sleeve 881 may also act as a spacer) by suitably positioning exterior form 800 at a known distance from interior form 600. Additionally, it may be desirable that tension tie assembly 880 includes a C-shaped clamp at each end (see reference numeral 888 in
[0127] As noted above with reference to other physical elements of a system for fabricating a reinforced structural member, the specific materials (such as, for example, aluminum, steel, other metals or alloys, glass or ceramics, fiberglass or other composites, and the like) and dimensions of the forms 800 described above in connection with
[0128]
[0129] During use, concrete or other construction slurry may be supplied to hopper 869 of trolley 860 with a traditional pump truck generally known in the construction arts. However, trolley 860, capable of linear translation along top chords 521 and 522 of top rail assembly 500, represents an innovation that facilitates efficient and proper placement of the slurry within the wall system assembly (i.e., between interior forms 600 and exterior forms 800) without spillage. As illustrated in
[0130] It will be appreciated that control of trolley 860 may be manual in some instances, for example; additionally or alternatively, trolley 860 may be controlled in part (or entirely) by remote control. Simple wired or wireless (e.g., radio frequency (RF), near-field communications (NFC), or other wireless network) systems may be used to control a suitably configured trolley 860. A battery or other power supply, a radio transceiver, and simple electronics (not shown in the drawing figures) may be incorporated into trolley 860 without undue experimentation or effort, as is generally known in the art of small radio-controlled toys, drones, or other apparatus.
[0131]
[0132] In accordance with the
[0133] Method 900 may proceed by attaching a column to a portion of the elongate base plate and bracing it in a substantially vertical orientation as indicated at block 902. It will be appreciated in this context that the column may have a height selected to accommodate a height of the structural member to be fabricated. As noted above in connection with
[0134] Method 900 may continue by attaching a top support to the top of the column as indicated at block 903. It will be appreciated that the top of the column in this context may generally be considered to be the free end opposite the elongate base plate or the foundation. As noted above, in some instances, it may be desirable to secure the top support (such as support 400 in
[0135] In this case, a rail assembly (such as depicted at reference numeral 500) may be selectively attached to the top support in a substantially horizontal orientation and substantially parallel to the longitudinal axis 271 of the structural member to be formed, as indicated at block 904. As described in detail above, this rail assembly may be configured and operative to suspend the form structures that may be used to define the structural member to be fabricated; it may also support a trolley, hopper, container, or other movable dispensing component that may translate linearly along the rail assembly to deposit construction materials for the structural member as set forth in detail above. Where structural members meet at a corner of a structure, one rail assembly for a first structural member may be cantilevered to extend beyond the other rail assembly for a second structural member; because the form elements are selectively suspended from the rail assembly (rather than built up from the foundation), it is not necessary that every rail assembly be at an identical height above the foundation to ensure a properly constructed structural member or to ensure consistency from one structural member to another in the same building, yet it nevertheless may be desirable that intersecting rail assemblies are made to abut each other at the same height, rather than overlaying one above the other.
[0136] As indicated at block 905, the method may continue by selectively suspending an interior form element (such as form elements 601, 602, and 604 in
[0137] As set forth above, the exterior form element and the interior form element may be selectively suspended from the rail assembly a distance apart, the distance between the interior form element and the exterior form element defining a baseline thickness of the structural member. Where a recessed region is included in the structural member, the interior form element may comprise a recess element (see, e.g., interior form 601 and recess element 620 in
[0138] As indicated by the dashed loop (reference numeral 995), the operation (or selected portions of the operation) depicted at block 905 may be iterated any number of times as desired or necessary to set the forms for fabrication of a structural member (such as reinforced structural member 200) having desired or required dimensions, specifically a length, such as along longitudinal axis 271.
[0139] In some implementations, method 900 may continue by selectively suspending a reinforcing element (such as wall plane reinforcement element 791, beam reinforcement element 792, post reinforcement element 793, or some combination of these) from the rail assembly intermediate the interior form element and the exterior form element as indicated at block 906. It may be desirable that this operation comprises positioning the applicable reinforcing element in a position relative to the exterior form element to support the structural member against a bending moment. As noted above, biasing a reinforcing system 700 (such as may comprise wall plane reinforcement element 791) towards the exterior surface may allow removal of material, enabling a structural member to take advantage of a recessed region and economizing on materials while still providing adequate structural support for both vertical (axial) loads as well as horizontal (lateral) loads. This arrangement is best illustrated in
[0140] As indicated by the dashed loop (reference numeral 996), the operation (or selected portions of the operation) depicted at block 906 may be iterated any number of times as desired or necessary to arrange sufficient reinforcing elements 791, 792, and 793 of reinforcing system 700 for fabrication of a structural member (such as reinforced structural member 200) having desired or required dimensions, specifically a length, such as along longitudinal axis 271.
[0141] Method 900 may conclude by depositing a slurry of construction material in a cavity between the interior form element and the exterior form element to form the structural member having the selected height as indicated at block 907. As noted above, this deposition may include use of a trolley configured and operative to ride along portions of the rail assembly. Linear motion of the trolly along the longitudinal axis of the structural member to be fabricated, as well as deposition rate of slurry from the trolley, may be controlled manually or electronically, for example, in situations in which the trolley is equipped with appropriate control electronics, motors, and a power source. In some instances, it will be desirable to keep the structural framework created by method 900 in place for the duration required for the construction material to set or cure. As noted above, the construction material slurry may be concrete, and curing duration may be a function of the recipe used, atmospheric conditions such as temperature and relative humidity (which may be affected by altitude, for instance), the manner in which the slurry was mixed and the age of the slurry before it was deposited at block 907, or a combination of these and a variety of other factors. The structural framework constructed in accordance with method 900 may be broken down when the construction material is sufficiently cured (not illustrated in
[0142] It is noted that the arrangement of the blocks and the order of operations depicted in
[0143] The foregoing system and method selectively place construction resources where they may be most structurally efficient. Specifically, a fabricated wall having selectively shaped recessed regions of a desired geometry may eliminate, or at least minimize, use of unnecessary concrete; these recessed regions also require placement of reinforcing elements (i.e., steel, fibers, fabric, or a combination thereof, for instance, such as illustrated in
[0144] Several features and aspects of a structural member, as well as systems and methods of fabricating same, have been illustrated and described in detail with reference to particular embodiments, arrangements, or implementations by way of example only, and not by way of limitation. Those of skill in the art will appreciate that alternative implementations and various modifications to the disclosed subject matter are within the scope and contemplation of the present disclosure. Therefore, it is intended that the present disclosure be considered as limited only by the scope of the appended claims.