METHOD FOR USING AERATED AUTOCLAVED CONCRETE IN RESIDENTIAL AND COMMERCIAL CONSTRUCTION

Abstract

A method for construction using a panel and plank system that may optionally be made of Aerated Autoclaved Concrete (AAC), wherein wall panels are delivered, erected and attached to structural forms and braced with properly designed shoring/struts with form ties and specifically designed panel ties. Intermediate bracing is installed at midspan locations where spans are short and there is a possibility of wall buckling. Floor/roof planks are set on top of the walls being cognizant of bearing surface requirements. The deformed and post-tension reinforcing steel is set/installed and any miscellaneous detailing is completed. Thin AAC panels can be installed as form liners for added insulation where dimensions accommodate them. Structural grout or small aggregate concrete is placed, consolidated/vibrated, and finished and allowed to cure to minimum required strengths. Roof pours are given a crown to allow proper drainage.

Claims

1. A method for constructing a building having at last one level, the level comprising an integral monolithic superstructure using planks and panels comprising an air-entrained or foam-based material in combination with cast-in-place concrete, the method comprising: placing a first set of planks, panels, or planks and panels in a vertical orientation on a construction site to define one or more vertical walls of the superstructure; providing and securing temporary shoring and formwork adjacent to the first set of panels and planks to define form cavities at selected intervals for cast-in-place columns and vertical reinforcement in the form of rebar or prestressed cables; placing a second set of planks, panels, or planks and panels in a generally horizontal orientation atop the first set to form at least a partial floor or ceiling surface, while leaving defined voids for the placement of cast-in-place beams; casting concrete into the form cavities between, adjacent to, and above the planks and panels to form structural columns, beams, and horizontal surfaces as a continuous monolithic pour, thereby integrating the cast-in-place concrete with the generally weaker air-entrained or foam-based panels and planks to form a composite structure; wherein the structural columns and beams formed by the cast-in-place concrete are sized and reinforced to accommodate increased the structural loading; and the horizonal beams and columns include rebar bent to form a cup-shape and including vertical rebar members extending vertically upwardly to at least a level at or sufficiently near the level of the upper surface of the floor planks to ensure that the, the upper ends of the vertical rebar elements are covered by later-poured concrete; and wherein the planks and panels remain in place while the concrete of the structural columns and beams is poured to function as formwork and after the concrete is cured, remain in place permanently to function as interior surfaces, exterior surfaces, or insulation, and wherein the cast-in-place concrete provides the primary structural strength of the superstructure.

2. The method of claim 1, wherein the planks and panels are comprised of an inert, inorganic, vapor-permeable material having a lower density than concrete, thereby reducing the potential for latent moisture condensation within the matrix and making the system suitable for environments containing humidity-sensitive electronic equipment.

3. The method of claim 1, wherein the cast-in-place concrete is formed in spatial relationship with the planks and panels to provide integrated vertical and horizontal structural support.

4. The method of claim 1, wherein the planks and panels function as stay-in-place formwork while the concrete is pour and during curing and thermal insulation thereafter, the cast-in-place concrete when cured providing the primary structural integrity of the superstructure.

5. The method of claim 1, wherein spaces formed between or adjacent to the planks and panels define initially empty regions to receive and hold for poured concrete and to act as forms for concrete cast-in-place columns, beams, or reinforcement zones that become part of a continuous concrete frame when the poured concrete is cured.

6. The method of claim 1, further comprising pouring cast-in-place concrete to form a network of structural beams atop or within the horizontal surface formed by the planks and panels.

7. The method of claim 1, wherein the planks and panels are composed of an inorganic, chemically stable, vapor-permeable, low-density, and non-combustible material that is exhibiting passive fire-resistant and thermally insulating.

8. The method of claim 1, wherein the temporary shoring is reusable and configured to support the planks and panels during concrete placement and curing, and is further adapted to support the staging of construction materials and placement equipment while the concrete is placed and cured.

9. The method of claim 1, wherein the cast-in-place concrete is poured into interconnected cavities to form a poured monolithic structural skeleton comprised of vertical and horizontal structural members that are monolithically interconnected without intervening mechanical connections between them and previously poured and cured concrete structural components using cold joints.

10. The method of claim 1, wherein the cast-in-place beams have a medial vertical plane through the length thereof and an average thickness at the medial vertical plane greater than the thickness of the adjacent floor or ceiling planks, thereby to provide adequate support for the floor or ceiling planks and to accommodate embedded utility sleeves, conduits, or service pathways for mechanical, electrical, or data systems.

11. The method of claim 1, wherein the method can employ a superstructure having a first intended size and a second other size, the method further comprising, at any time prior to the step of pouring the concrete, changing the first intended size of the superstructure to the second size by using supplemental or different configurations of shoring, bracing, or additional formwork.

12. A method for constructing a building having at least two vertically adjacent levels, each of the two vertically adjacent levels comprising an integral monolithic superstructure using planks and panels comprising an air-entrained or foam-based material in combination with cast-in-place concrete, the method comprising, for each level: placing a first set of planks, panels, or planks and panels in a vertical orientation on a construction site to define one or more vertical walls of the superstructure; providing and securing temporary shoring and formwork adjacent to the first set of panels and planks to define form cavities at selected intervals for cast-in-place columns and vertical reinforcement in the form of rebar or prestressed cables; placing a second set of planks, panels, or planks and panels in a generally horizontal orientation atop the first set of planks, panels, or planks and panels to form at least a partial floor or ceiling surface, while leaving defined voids for the placement of cast-in-place beams; casting concrete into the form cavities between, adjacent to, and above the planks and panels to form structural columns, beams, and horizontal surfaces as a continuous monolithic pour, thereby integrating the cast-in-place concrete with the generally weaker air-entrained or foam-based panels and planks to form a composite structure; wherein the structural columns and beams formed by the cast-in-place concrete are sized and reinforced with rebar, wire mesh and/or pre-tensioned bars or cables to accommodate structural loading; and the horizonal beams include at least rebar bent to form an upwardly open longitudinally-elongated cup-shape, the beams further including vertical rebar members extending vertically upwardly to at least a level at or sufficiently near the level of the upper surface of the floor planks to ensure that the upper ends of the vertical rebar elements are covered by later-poured concrete when cured; wherein the planks and panels remain in place when the concrete of the structural columns and beams is poured to function as formwork until the concrete is cured, and thereafter remain in place after the cast-in-place concrete of the structural columns and beams is cured to function as interior surfaces, exterior surfaces and/or insulation, and wherein the cast-in-place concrete provides the primary structural strength of the superstructure, and wherein, once the panels, planks and forms are positioned and held in place to define the cavities for forming the cast-in-place beams and columns for the at least two levels, concrete is poured in place in all the cavities of the at least two levels in a substantially continuous manner to form, when the concrete is cured, a poured monolithic structural superstructure encompassing the at least two adjacent levels comprised of vertical and horizontal structural members that are monolithically interconnected without intervening mechanical connections between them and or with previously installed structural components using cold joints.

13. A method for constructing a building having between three and twenty vertically adjacent levels, all the vertically adjacent levels together comprising an integral monolithic superstructure using planks and panels comprising an air-entrained or foam-based material in combination with cast-in-place concrete, the method comprising, for each level: placing a first set of planks, panels, or planks and panels in a vertical orientation on a foundation for the lowest level or on the next lower level for all successively higher levels, to define one or more vertical walls of the superstructure; providing and securing temporary shoring and formwork adjacent to the first set of panels and planks to define form cavities at selected intervals for cast-in-place columns and vertical reinforcement in the form of rebar, wire mesh and/or prestressed cables or bars; placing a second set of planks, panels, or planks and panels in a generally horizontal orientation atop the first set of planks, panels, or planks and panels to form at least a partial floor or ceiling surface, while leaving defined voids for the placement of cast-in-place beams; casting concrete into the form cavities between, adjacent to, and above the planks and panels to form structural columns, beams, and horizontal surfaces as a continuous monolithic pour, beginning at the lowest level and then each successively higher level, thereby integrating the cast-in-place concrete with the generally weaker air-entrained or foam-based panels and planks to form a composite structure; wherein the structural columns and beams formed by the cast-in-place concrete are sized and reinforced to accommodate the structural loading; wherein the horizonal beams include rebar bent to form a cup-shape and including vertical rebar members extending vertically upwardly to at least a level that ensures that the upper ends of the vertical rebar elements are covered by later-poured concrete for the beam; wherein the planks and panels remain in place when the concrete of the structural columns and beams is poured to function as formwork until the concrete is cured, and thereafter remain in place after the cast-in-place concrete of the structural columns and beams is cured to function as interior surfaces, exterior surfaces or insulation, and wherein the cast-in-place concrete provides the primary structural strength of the superstructure; and wherein, once the panels, planks and forms are positioned and held in place to define the cavities for forming the cast-in-place beams and columns for the at least two floors, concrete is poured in place into all the cavities of the levels, beginning with the lowest level and then the next higher level in order, in a substantially continuous manner, to form, when the concrete is cured, a poured monolithic structural superstructure encompassing the vertical and horizontal members monolithic structural members of all level such that they are monolithically interconnected without intervening mechanical connections between them or to other previously installed structural components using cold joints.

14. The method of claim 1, wherein the one or more vertical walls of the superstructure include at least two spaced-apart vertical exterior walls, each of which is disposed in at least two separate axially-aligned sections having opposed and spaced-apart ends to form a gap between them, wherein the method further comprises: placing an internal demising wall comprised of panels formed of air-entrained or foam-based material, the panels having respective ends, at least one of which ends being positioned adjacent an interior side of the gap to at least partially close-off the interior side of the gap; and placement of interior and exterior vertical forms covering remaining open internal and external portions of the gap to form a closed-at-the-sides vertically-oriented cavity to receive and hold poured concrete to form a cast-in-place column in the cavity.

15. A method for creating a building having an integral monolithic superstructure having between one and twenty levels, the method comprising the steps of: placing a foundation having a plurality of predetermined horizontally spaced apart column locations having a width to support a lowest level; on the lowest level, placing a plurality of predetermined horizontally spaced apart column locations having a width thereon, each of which is axially aligned with one of the plurality of predetermined horizontally spaced apart column locations having a width, for each successively higher level of the between one and twenty levels, beginning at the next higher level: setting a first set of vertically oriented shoring having a width adjacent to an interior side of the horizontally spaced apart column locations, the width being sufficiently wide to cover the interior side of each respective space for the vertical supporting columns to be formed in the horizontally spaced apart column locations and having a width, and a portion of the ends of the first set of construction material on either side of each of the horizontally spaced apart column locations; placing a first set of vertically oriented construction materials that include planks, panels, or planks and panels comprising a foam material and having a length, width, ends, a thickness and lower and upper edges, the first set of construction materials for the lowest level being supported by the foundation, and the first set of vertically oriented construction materials for each successively higher level being supported by the next lower level, the first set of vertically oriented construction materials for each level forming one or more vertical walls of the integral monolithic superstructure, the ends of the first set of construction materials being spaced apart horizontally and endwise on the foundation for the lowest level and on the next lowest level for each successively higher level, at the predetermined horizontally spaced apart column locations to leave a sufficient space for the vertical supporting columns but sufficiently close together that the first set of vertically oriented shoring covers a portion of the ends of the first set of construction material on either side of each of the horizontally spaced apart column locations; setting a second set of vertically oriented shoring having a width adjacent to an exterior side of the horizontally spaced apart column locations, the width being sufficiently wide to cover the exterior side of the space for the vertical supporting columns and a portion of the ends of the first set of construction material on either side of each of the horizontally spaced apart column locations such that the space for each of the vertical supporting columns is substantially enclosed on all vertical sides; placing a second set of construction materials that include planks, panels, or planks and panels on an inner portion of a topmost edge of the first set of construction materials to form a horizontal surface of the integral monolithic superstructure while leaving an outer portion of the top edge of the first set of construction materials uncovered by the horizontal surface, the horizontal surface having a thickness and an upper surface having a height greater than the height of the topmost horizonal edge of the first set of construction material; placing a perimeter vertically oriented and horizontally elongated form around the topmost portion of the exterior perimeter of the upper portion of the first set of construction materials of each level, the form having a top edge higher than the upper surface of the horizontal surface, the form in combination with the topmost horizontal edge of the first set of construction materials uncovered by the horizontal surface of the second set of construction materials, the adjacent edge of the horizontal surface, and the second set of vertically oriented shoring, forming an open-at-the-top generally circumferential space, the bottom portion of which is in communication with the upper ends of each of the horizontally spaced apart column locations; beginning with the lowermost level, pouring mortar, concrete or a mix thereof into the open-at-the-top portion of each generally circumferential space at the top of the level, to substantially fill it and each of the horizontally spaced apart column locations of the level, and to cover at least a portion of an upper surface of the horizontal surface of the second set of construction materials for the level with a predetermined thickness of the mortar, concrete or a mix thereof; and then, for each successively higher level, pouring mortar, concrete or a mix thereof into an open-at-the-top portion of each generally circumferential space at the top of the level, to substantially fill it and each of the horizontally spaced apart column locations of the level, and to cover at least a portion of an upper surface of the horizontal surface of the second set of construction materials for the level with a predetermined thickness of the mortar, concrete or a mix thereof, until the mortar, concrete or a mix thereof has filled all the generally circumferential spaces and horizontally spaced apart column locations for each level, the mortar, concrete or a mix thereof being poured in a substantially continuous manner to form, when cured, a poured monolithic superstructure encompassing all levels and being comprised of vertical and horizontal monolithic structural members that are monolithically interconnected without intervening mechanical connections between them or to previously installed structural components using cold joints, and, for each level; and removing the first set of vertically oriented shoring and the second set of vertically oriented shoring while permanently retaining the foam material as part of the completed building having an integral monolithic superstructure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:

[0015] FIG. 1 depicts a front elevational view of a wall at an outside corner with forms according to an embodiment of the present disclosure;

[0016] FIG. 2 depicts a front elevational view of a wall with forms and intermediate bracing/shores according to an embodiment of the present disclosure;

[0017] FIG. 3 depicts a plan view of a wall and a plurality of floor planks according to an embodiment of the present disclosure;

[0018] FIG. 4 depicts a section view of the top of a panel wall and side edge of floor plank according to an embodiment of the present disclosure, taken along site line 4-4 in FIG. 3;

[0019] FIG. 5 depicts a plan view of a corner of the wall of FIG. 1 according to an embodiment of the present disclosure;

[0020] FIG. 6 depicts a plan view of a panel wall system with forms according to an embodiment of the present disclosure;

[0021] FIG. 7 depicts a plan view of a wall and form at an intermediate integral column according to an embodiment of the present disclosure;

[0022] FIG. 8 depicts a plan view wall and concrete column with a form according to an embodiment of the present disclosure;

[0023] FIGS. 9A and 9B depict a front elevational view of a wall and shoring form and anti-buckling stiffener and intermediate wall shoring according to an embodiment of the present disclosure;

[0024] FIGS. 9C and 9D depict a plan view of a wall and form with a strut according to an embodiment of the present disclosure;

[0025] FIG. 10A depicts a front elevational view of a wall and a shoring form according to an embodiment of the present disclosure;

[0026] FIG. 10B depicts an enlargement of section A of FIG. 10A;

[0027] FIG. 11 depicts a plan view of an end of a wall and form with a strut cleat according to an embodiment of the present disclosure;

[0028] FIG. 12 depicts a perspective view of a straight panel tie according to an embodiment of the present disclosure;

[0029] FIG. 13 depicts a perspective view of a corner panel tie according to an embodiment of the present disclosure;

[0030] FIG. 14 depicts sectional view of a form and a fastener assembly according to an embodiment of the present disclosure;

[0031] FIG. 15 depicts a section view of a panel wall with a ring/perimeter beam form and the bearing end of a floor plank according to an embodiment of the present disclosure;

[0032] FIG. 16 depicts a side cross-sectional view of an integral floor plank beam and wall at an integral wall column and support system according to an embodiment of the present disclosure;

[0033] FIG. 17 depicts a section view of the floor planks at the integral floor plank beam and at a retention tie/rod for systems suspended from the AAC roof or upper story floor system and support system with floor planks according to an embodiment of the present disclosure;

[0034] FIG. 18 depicts a schematic plan view of a walled structure having a demising wall in a generally middle section thereof, according to an embodiment of the present disclosure;

[0035] FIG. 19 depicts a schematic plan view of the walled structure depicted in FIG. 18, with floor planks added on top of the walls, and with the corner forms and demising wall mid-wall forms omitted for clarity, showing a space between the two middle floor planks, and prior to pouring of any concrete for the integral monolithic superstructure, according to an embodiment of the present disclosure;

[0036] FIG. 20 depicts an elevational section view through the mid-wall portion of the demising wall and middle floor planks, taken through 20-20 of FIG. 19, after adding rebar and pouring concrete in the space between the middle floor planks to form a load-bearing beam, the concrete also be poured over the planks to form a floor, according to an embodiment of the present disclosure;

[0037] FIG. 21 depicts an elevational section view of the mid-wall portion of the demising wall and middle floor planks, taken through 21-21 of FIG. 19, after adding rebar and pouring concrete in the space between the middle floor planks, further including an upper form to create a thicker load-bearing beam than the load-bearing beam depicted in FIG. 20, the concrete also being poured over the planks to form a floor, according to an embodiment of the present disclosure;

[0038] FIG. 22 depicts an elevational section view of the mid-wall portion of the demising wall and middle floor planks, taken through 22-22 of FIG. 19, after adding rebar and pouring concrete in the space between the middle floor planks to form a load-bearing beam, the beam including lower T portion to both provide a thicker load-bearing beam than the load-bearing beam depicted in FIG. 20 and ledges to support the edges of the middle floor planks, the concrete also being poured over the planks to form a floor, with temporary braces, according to an embodiment of the present disclosure;

[0039] FIG. 23 depicts an elevational section view of the exterior wall and one of the floor planks, taken through 23-23 of FIG. 19, after adding rebar and pouring concrete in the space between the most-outside floor plank, between the edges of two wall panels for an upper floor, and an outside form, to form a load-bearing beam to support an upper floor, with temporary braces, according to an embodiment of the present disclosure;

[0040] FIG. 24 depicts an elevational section view of the mid-wall portion of the demising wall and middle floor planks, taken through 24-24 of FIG. 22, after adding rebar and pouring concrete in the space between the middle floor planks to form a load-bearing beam, and two upper wall panels, the beam including lower T portion to both provide a thicker load-bearing beam than the load-bearing beam depicted in FIG. 20 and ledges to support the edges of the middle floor planks, with two wall panels for an upper floor, the concrete also being poured over the planks to form a floor, which temporary braces, according to an embodiment of the present disclosure;

[0041] FIG. 25 depicts an elevational section view of the mid-wall portion of the demising wall and middle floor planks, taken through 25-25 of FIG. 19, after adding rebar and pouring concrete in the space between the middle floor planks to form a load-bearing beam to support a wall of an upper floor, the beam including a lower I portion to both provide a thicker load-bearing beam than the load-bearing beam depicted in FIG. 20, the concrete also being poured over the planks to form a floor, with temporary braces, according to an embodiment of the present disclosure; and

[0042] FIG. 26 depicts an elevational section view of the mid-wall portion of the demising wall and middle floor planks, taken through 26-26 of FIG. 18, after adding rebar and pouring concrete in the space between the middle floor planks to form a load-bearing beam, the beam including an upper I portion to provide a thicker load-bearing beam than the load-bearing beam depicted in FIG. 20 to support a wall of an upper floor, the concrete also being poured over the planks to form a floor, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0043] Disclosed herein is a method to construct and assemble an integrated monolithic superstructure using panels and planks, where the panels, planks, or both panel and planks are made of aerated autoclaved concrete (AAC).

[0044] The method can include developing a structure that is conceptually designed for a more conducive application of the System. An assessment of purpose, required design criteria, space needs, etc. and the development of the conceptual design should be guided in a manner that is conducive the use of this system. If the design is already conceptually established, then a skilled, properly trained architect, engineer, qualified contractor, or AAC rep should assess the conceptual design and design criteria and make recommendations that render the use of the system more practical for the specific application.

[0045] The AAC manufacturer adjusts their product characteristics (compressive strengths and internal reinforcing requirements), the manufacturer can design material characteristics to meet thermal and compressive strength requirements for the building and local code criteria/standard. Top wall panels should have a higher compressive strength where needed to accommodate live and dead loads during construction activities. A structural design technician designs the IMS to accommodate the performance standards of the structure, the performance standards, and deflection criteria of the substructure to minimize failures or cracking. Bearing soils tests are always required.

[0046] The AAC planks and panels are manufactured in the factory, then cut to exact dimensions (but minimizing the number of unique dimensions) required for assembly to eliminate the process of field cutting to fit. Standard sizes can be used, which also allows for the interchangeability of panels or planks. Pre-cutting to exact lengths at the factory allows for fashioning panels/planks in an environment with the facilities to perform fashioning quicker and more efficiently. Pre-cutting also allows the field erectors to work quickly and without delays caused by custom field cuts. Limited Uniform sizes, consistent with typical residential room dimensions, allow for easy staging on delivery vehicles, easy interchangeability of damaged or missing panels/planks, and easy coordination at the jobsite. Limited Uniform sizes also allows AAC distributors to stock panels and planks, which would otherwise be considered custom manufactured and potentially eliminate delays caused by remanufacturing of damaged or missing panels and planks.

[0047] Panels and planks are reverse staged (last loaded on the truck are the first set on in place on site) on delivery vehicles so that, when construction site conditions permit, panels and planks can be picked from the truck and set directly in place. AAC is a low strength concrete that is damaged relatively easily. Repairs can be made but take time and cause delays. Reduced handling means a reduced risk of damage and delays. Moving materials multiple times takes time and causes delays. Reverse staging on delivery vehicles mean products can be set in place right from the delivery vehicles, eliminating delays caused by staging materials multiple times, and the cost of repairing damage caused by excessive handling. Dual tandem, short-wheel-based, soft-ride trailers allow delivery to areas where road access is tight (such as residential neighborhoods) because one trailer can be dropped, while one is delivered, and minimizing damage from transport.

[0048] Prior to delivery of components an appropriate design foundation or substructure is constructed. AAC is non-ductileit will only accommodate a minimum amount of deflection before it cracks, this is especially true for wall panels. The performance standards and deflection criteria of the substructure should be such that it minimizes failures or cracking. Bearing soils tests are always required to determine substructure design criteria. Additionally, bond-breaking materials and thin expansion joint materials are used in strategic locations. These materials help arrest and isolate potential movement throughout the IMS wall system. They also mitigate cracking caused by the thermal expansion and contraction differentials of the different materials.

[0049] Prior to placing any wall panels, vertical wall forms are erected at strategic locations (corners, mid-wall integral columns, and as mid span bracing to prevent buckling on longer wall spans). They are set, braced, and plumbed using a combination of rigid or cable struts and shores, and specially designed ties and connections 205. Shoring and braces are anchored to the substructure or flooring system using properly designed removable anchors, or adjacent wall panels. These forms and braces serve two purposes: to function as forms for the cast-in-place structural grout/concrete mix for the IMS, and to plumb and temporarily and safely brace and shore the wall systems, and allows for planks to safely bear on panel walls. The forms and braces hold the panels in an arrangement that is in accordance with the floor plan. One of the key factors of the system is the monolithic casting of the entire Internal/Integral Monolithic Structure Superstructure at one time. The forms sandwich the ends of the panels (one form on the outside face and one on the inside face) and are held in place with through-wall form ties at each horizontal panel joint. The form ties can be re-usable or disposable snap ties, or re-usable She-Bolt, Wing-Nut or other removable through wall or sleeved tie. The forms are specifically designed with elongated and oversized form tie holes at panel joint locations to accommodate a limited amount of field tolerance deviations, and to allow the walls to be re-plumbed after the panels are in erected. This is important because the floor and roof planks can be cut to size at the factory, and the bearing requirements for the end of the panels is specific. Field adjustment capabilities are needed to make sure that the distance between the tops of the bearing walls is exact. Plumbing, temporarily and safely bracing, and shoring the wall systems allows erection of the wall panels and floor planks continuously without interruption, and without the use and cost of a permanent external superstructure. As shown in FIG. 6, these forms & struts, creating form systems 105, st securely brace/shore the walls to prevent any movement or buckling (or other failure) while the floor planks are set on the top edge of the walls. This is important because workers can be working on the planks that have not been secured in place by the IMS. Struts are anchored to forms/shoring and are secured to the concrete slab or foundation using an imbedded receiver with a removable anchor 109, or expansion anchor or shield. Struts may also be through-bolted 111 to the bottom panel near the slab and adjacent to a perpendicular panel wall. Corner Forms can be set with the inside corner set on a to removable pivot shim, or embedded levelling bolt to allow the contractor to plumb walls and where necessary, tilt walls inward to meet minimum surface bearing areas for the planks that rest on the tops of the walls. Take as-built elevations at any location where panels can be set. Concrete should be flat and level. Surface needs to be within +/ of 10 feet in elevation to prevent point loads and spalling, or panel deflection. One way to assure the surface is within the parameters is to install chamfers trips at the exact grade of the concrete along the interior surface of the perimeter beam forms. If the bearing surface is not precise, then obtain exact as-built elevations, determine the highest point of the perimeter of the slab, set glazing shims at 10 o.c. set to the exact elevation of the highest point, lay a bed of mortar in between shim locations, and use a concrete screed to create a precise bearing surface for the panels.

[0050] Specific pre-erection tasks are undertaken to prepare the area. Wall panels 101 are tongue and groove to allow precise edge-to-edge fit and alignment. Some field fashioning and panel prep is required to accommodate the form ties 103 that pass through the walls at the panel joints 203, and panel ties 805 that connect panel ends to adjacent panels or to the integral column. Wall panels 101 arrive at the job site, reverse staged on delivery vehicles. The preferred method is to set the panels 101 and planks 1201 directly from a truck even if it requires using 2 cranes to expedite unloading. Not all site conditions will allow this. The wall panels 101 can be set on edge horizontally, with a gap of 6-10 between the ends of the panels. This gap can eventually form the integral column element 307 of IMS (see FIG. 5). Wall panels 101 can be braced using struts 107 and forms 901 that have form ties 103 that extend through the wall system at the panel joints 203 (see FIGS. 1 and 6). The struts 107 can be fastened with removable lag bolts or other appropriate concrete anchors 109 to the foundation, or to the first (bottom) panel with a though-bolt 207 after the first panel is set. All anchors 109 and connections 801 should meet minimum requirements for the application and anchor substrate. If needed, the panels 101 are separated on the truck using a special lever/tool to give the worker space to prep the panel. Remove approximately 12-16 inches of panel tongue at each end of each panel (except the top and at wall openings) to accommodate the attachment of a Panel Tie 805, and form tie. An appropriate panel tie 805 (exact type, size, configuration, gauge, and material varies by location and environment) is attached on one panel end along the centerline of the top edge of the panel using standard/appropriate AAC fasteners 1001 (see FIG. 12). The panel tie 805 can extend about 18 beyond the end of the panel. This panel tie 805 can be fastened to the opposing panel. These panel ties 805 secure the ends of two panels 101 together and cross the gap between the panel ends (the gap of 6-10 that eventually becomes the concrete column element of the IMS). These Panel Ties 805 are approximately 30 long, made of a single continuous piece, and designed and fabricated so that the ends lay flat on the top edges of opposing panels, however the center section (the section that passes through the gap in which concrete can be poured) is twisted vertically to allow poured concrete to fall or pass by the Panel Ties and allow the concrete to completely fill the formed column (mid-wall columns 1207 and corner columns 1209) and properly consolidate within the formed cavity. Different shapes of panel ties 1101 can be used to form corners as seen in FIG. 13. Panel ties may also be bent in the shape of an L and discontinuous to allow some field tolerance flexibility. IN this case, two separate panel ties will be fastened to the ends of two opposing panels at the IMS column and will anchor in the cured cast in place concrete.

[0051] The vertical structural forms 401 have form ties 103 at four locations at each panel joint 203 and additional locations on walls that require intermediate anti-buckling bracing (see FIGS. 9A and 9B). The two outer form ties 103 (farthest away from the gap or end of the panels) allow the wall to be erected and braced from one side of the wall. These form ties 103 should be recessed below the top edge of wall panel, to allow clearance for the panel ties/connectors 805/801 that lay flat on the top edge of the panel at the integral column 803 locations (see FIG. 10B). The form ties should be sleeved to allow easy removal (use She-bolts or through bolts) (see FIGS. 9C and 9D). The tie holes 301 in the forms should be oversized (as seen in FIG. 7) to allow for field tolerance deviations and to plumb forms. The connectors 801 securing the forms 401 can be recessed into the forms 401 to allow the wall panels 101 to fit flush on the inside surface of the forms 401 without scraping against the screw or bolt heads. A piece of plywood 701 can be placed on the exterior of the wall panels 101 to ensure the forms 401 do not damage the wall panels 101. The two interior form ties 103 (closest to the gap) are designed to secure the outer wall form 201 after the panels 101 are erected and the reinforcing steel is set (see FIG. 8). Along the centerline of the vertical forms are holes for conical (or other) snap-ties 305 to retain outer form panel and to prevent form blow-outs or bulging. Workers may cut a receiver for form ties 103, remove another section of the tongue, and cut four shallow grooves at the top edge of the panel to accommodate the through-wall form ties 207 (or the sleeve 601) that pass through the panel joints 203 at these locations. Recessing the form ties 103 in the top edge of the panel is necessary so that the form ties 103 do not interfere with the panel ties 805 that are fastened to the top edge of the panel. The top panel requires additional prep to accommodate the horizontal c.i.p. perimeter/ring beams 1205 at the top of all walls and perimeter of the floor/roof planks. A worker may cut a reglet/receiver using a dado blade, or appropriate router bit, for the form ties (snap ties, she-bolts 303, through-wall sleeves 601, etc.). Alternatively, drill and set shield for perforated form strap may be used.

[0052] Once panel setting & erection (preliminary cutting, pre-drilling, trimming, etc.) for the panel ties 805, form ties 103 & anchors/fasteners 1301 has been completed, and a panel tie 805 is connected to one end of the panel 101, the panel 101 is hoisted to its final placement location in the system. Another worker can receive and guide the panel into place. That same worker can also: install form ties 103 at the ends of the panels; install form ties 103 at the locations of the intermediate anti-buckling bracing where needed; attach the loose end of the panel tie 805 on this panel 101, to the previously set panel on the opposite side of the gap; top panel-install form tie or perforated strap or sleeve for removable/reusable form tie; secure the outer form ties 103 with compatible form-tie ends (wale, wing nuts, or other base that allows minor adjustment and minor wall width fluctuations); secure and tighten the form tie 103 on the lower edge of the wall panel; install intermediate anti-buckling bracing/stiffeners 401/shoring struts 107/anchors 109 at midspan locations when/where there is a possibility of wall buckling (see FIGS. 2 and 6); and install chamfer strips where forms meet panels to create a reglet for crack isolation and caulking. Repeat this process for all panels 101. For top panel preparation see forming perimeter c.i.p. ring/perimeter beam 1205 in FIG. 11. Install the preferred form ties 103 on the top edge of the top panel 101 at specific locations to receive and secure perimeter beam forms 901. Apply bond-breaker 309 crack isolation membrane, expansion joint filler 209 as required to the surfaces of the AAC that come in contact with the case in place concrete of the IMS. Install column reinforcing per engineered drawing requirements. Patch, seal and form any locations that might have a potential for concrete slag leakage. Install AAC thin panels as form liners for additional insulation.

[0053] Floor plank erection and setting may be seen in FIGS. 3,4, 14-17. The planks are set on top of the walls being cognizant of bearing surface requirements. The planks can be used to form a horizontal surface of the IMS. Take as-built dimension of the distances between tops of the wall panels to be certain that minimum bearing surface requirements can be met. Adjust the struts 107 in or out to position the tops of the wall panels to confirm that minimum bearing surfaces are achieved. Walls may be out of plumb slightly to accommodate these requirements. If greater adjustments are required, loosen form tie bolts/wales/etc., adjust struts, then re-secure form ties. Start with the end planks 1201, placing planks 1201 side-by-side at both ends of the structure and work towards the integral floor beam 1203 (see detail 2D for section). Lay the first planks 1201 with the long edge of the plank 1201 either overlapping with the top edge of the end wall if the wall is lower than the bottom edge of the spanning plank, or just inside and abutting the upper edge of the parallel wall, if the wall is taller than the bottom corner/edge of the spanning plank (see FIGS. 4 and 15). Lay planks side-by-side starting at both end walls and progress to meet a midspan location, where there can be a strategic intentional gap 1305 that is designed to accommodate and absorb field tolerance issues. Gap 1305 may also create a structural load bearing beam 1203 that can accommodate concentrated loads from permanent construction above (column, stair system, etc.), where this beam is designed to be load bearing (deformed reinforced steel or post tension cabling). The beam should coincide with an integral wall column, when possible. The Soffit of this section shall be formed 1601 (see FIG. 16) from above using plywood 1501 that is suspended from above using adjustable form ties 305, cables 1701, rebar spanning the plank gap 1603, and tensioning devices 1703 to pull the forms flush and tight against the underside of the planks (see FIG. 17). Install chamfer strips along each panel edge, if preferred. Seal, patch, and form any gaps or areas where placed concrete slag may leak. Pre-run MEP service or anchors or floor penetrations (run/install after reinforcing steel is installed): pre-drill and install all anchors that can be used to suspend systems from the ceiling below; contact material manufacturer for location or reinforcing; run service conduit and plumbing as needed; install floor heating systems if utilized; form the perimeter of any floor openings such as stairs, scuttles, chase locations, roof/floor penetrations for Mechanical/Electrical/Plumbing (MEP); and install block-outs at any locations where other service penetrations might be required. Supplemental reinforcing and welded wire fabric (WWF) might be required a blockout corners and points prone to cracking.

[0054] The deformed and post-tension reinforcing steel is set/installed and any miscellaneous detailing is completed. Lay and chair reinforcing per that manufacturer's and/or structural engineer's requirements. Install perimeter reinforcing steel in the perimeter beams. Lay WWF if there is any possibility that the concrete topping 1705 may develop cracks. Reinforce openings as detailed by engineer. Install other imbedded devices, shoring/bracing anchors, davits, etc.

[0055] Remaining wall perimeter beam forms are installed. Fastener cleats 1303 on the face of the walls a distance below the top edge of the walls to support the perimeter beam form boards (as seen in the sectional view of FIG. 14), such that the top of the form boards is at the finish grade of the concrete topping 1705. The forms 901 can be secured flush to the wall panels 101 with plywood 1501. Forms must be precisely set if additional wall panels are to be erected (see FIG. 10A). Forms shall interlock at the end edges to prevent blow-outs. Forms are pre-drilled at specifical location to line up with the form tie locations. Form tie holes may be oversized to accommodate field tolerances. AAC panels may be pre-drilled to accept anchor and wall tie at these locations. Thin AAC panels may be installed as form liners for added insulation where dimensions accommodate them (8 and thicker wall panels). Bond breaker and expansion joint materials may also be installed to arrest/isolate cracks caused by cyclical movement and mitigate panel cracking.

[0056] One or more additional levels can be added to the building by repeating the above steps with further sets of planks and panels on top of the first level built. Additional levels can be the same size as the first level or a different size. If the additional level is the same size as the first level, the additional level walls can be placed at the point where the first level vertical walls meet the horizontal surface formed by the planks.

[0057] Place structural grout or small aggregate concrete mix. Consolidate, vibrate, and finish per engineering requirements. Allow concrete to cure to minimum required strengths. Mix strength of the concrete may be determined by the engineer. Roof pours are given a crown and slope of approximately 1/16 to per ft to allow proper drainage.

[0058] Forms, bracing, shoring, removable anchors and struts are removed. Concrete is patched, additional thin AAC cladding is applied over exposed concrete to provide added insulation and a uniform surface for applied finishes.

[0059] Further embodiments of the invention depicted in FIGS. 18 to 26 are described in detail below.

[0060] FIG. 18 is a simplified plan view of the top of one level of an exemplary walled structure 1800 (which can have one just level, or multiple similar levels, up to twenty or more). As depicted, the walled structure 1800 is rectangular in shape, with four sides, two being short and two being long, all of which are comprised of six external wall sections 1805.

[0061] Each of the wall sections 1805 can be comprised of horizontally-stacked panels 101 (only the topmost of which can be seen in FIG. 18), which can be made from an air-entrained or foam-based material, which can be AAC, in combination with later-poured cast-in-place concrete in strategically-placed open-at-the-top gaps 1810 and 1817. Gaps 1810 and 1817 are similar to gaps 1305 of FIGS. 1-17, which are used to form, ultimately, mid-wall columns 1207 and corner columns 1209, respectively, using poured concrete, as previously described. As with the embodiments depicted in FIGS. 1-17, the horizontally-stacked panels 101 can have tongue and groove edges, such as depicted in FIG. 4, for example, though this cannot be seen in the plan view of FIG. 18.

[0062] As with the embodiments of FIGS. 1-17, the panels 101 forming wall sections 1805 of FIG. 18 can be of a standardized size and configuration to achieve interchangeability and simplified stocking and construction.

[0063] In the example depicted in FIG. 18, the walled structure 1800 formed by the wall sections 1805 can be an elongated rectangular shape. Even though the lengths of all the panels 101 forming the wall sections 1805 are, as depicted, standardized and therefore of equal length, it is simple to use the wall section 1805 to form both the short sides and the long sides. To form the long sides of the rectangular shape of the building (as viewed in plan), which can be comprised of two separate wall sections 1805 comprised of horizontally-stacked panels 101, which are axially-aligned with their respective ends opposed and spaced apart, as depicted, with an intentional gap 1810 between the panel ends of approximately 6-10 inches, that will eventually be filled with concrete to form the concrete column element of the IMS. Where greater strength of the column elements is desired, such as for a multi-level structure, the gap 1810 can be made larger to any degree desired or required by strength requirements.

[0064] At the corners of the walled structure 1800, there are intentional gaps 1817 between the panel 101 ends of approximately 6-10 inches, that will eventually be filled with concrete to become the corner concrete column elements of the superstructure of the IMS). Where greater strength of the column elements is desired, such as for a commercial building or a multi-level structure, the corner gaps 1817 can be made larger to any degree desired or required by strength requirements.

[0065] The gaps 1810 and 1817 are partially enclosed by the opposed ends of the panels 101 forming wall sections 1805. To complete closure of the sides of the gaps 1810 and 1817, forms 201 and/or 901 can be placed at the inside and outside sides of the remaining open areas of mid-wall gaps 1810 and corner gaps 1817 to form a closed-at-the-sides and open-at-the-top gap. Forms 201 and 901 can be the same construction as the examples depicted in FIGS. 1-17, and can be held in place using the same type of form ties 103 and/or snap ties 305 depicted in FIGS. 1-17, although, for simplicity and clarity, form ties 103 and 305 and the details of construction of the forms 201 and/or 901 are not depicted in FIG. 18.

[0066] As depicted in FIG. 18, the walled structure 1800 can also include an internal demising wall section 1805, disposed generally in the middle region of the structure 1800. The demising wall 1805 is disposed between the wall sections 1805 and can have an intentional gap 1810 between the opposed ends of the two axially-aligned sections 1805 on each side that form the long sides of the rectangular-shaped structure.

[0067] As shown, the ends of the panels 101 of the demising wall section 1805 partially enclose an inside-facing portion of the gaps 1810, the remaining sides of the gaps being closed by forms such as forms 201 and/or 901. These forms are maintained in place by, for example, ties 103 and/or snap-ties 305, not shown in FIG. 18 but which are depicted in FIGS. 1-17, as previously described. This will then form closed-at-the-sides and open-at-the-top gaps, to later receive poured concrete to form the columns of the integral superstructure.

[0068] Of course, using the same technique, any number of arrangements of external walls sections 1805 and/or demising wall sections 1805 can be employed to form a great variety of shapes and sizes for the walled structure, not limited to the rectangular shape and single demising wall depicted.

[0069] Turning now to FIG. 19, FIG. 19 depicts a simplified schematic plan view of the walled structure 1800 depicted in FIG. 18, in a later stage of construction, with floor planks 1201 added on top of the top-most panels 101 of the walls, showing an intentional space between the two middle floor planks 1201, prior to pouring of any concrete for the integral monolithic superstructure. For clarity and simplicity and clarity, the corner forms and demising wall mid-wall forms 201 and/or 901 are omitted for clarity.

[0070] As depicted, planks 1201 can be placed with their ends extending over a portion of the two external wall sections 1805 forming the long sides of the walled structure 1800 for support during construction and thereafter. At the short sides of the rectangular structure, the nearest edge of the planks 1201 nearest the short side wall sections 1805 can be placed on or near the upper edge of the of the short side wall sections 1805. Similarly, in the interior of the structure, at the demising wall 1805, the nearest edge of the planks 1201 nearest the demising wall 1805 can be placed on or near the upper edge of the of the demising wall 1805.

[0071] FIG. 19 depicts two alternative placement of the planks 1201, where two sections, one section on the left side of the figure, and one section on the right side of the figure, which have rows of planks 1201 that are, respectively, orthogonally aligned. Of course, it is also possible to configure all the planks 1201 on a level so that they are aligned, or the use different alignments of the planks 1201 on different levels.

[0072] For clarity and simplicity, FIG. 19 doers not depict forms 201 and/or 901, or the shoring, braces, and/or anchors, though it is understood that, during construction, such forms, shoring, braces, and/or anchors would be at least temporarily installed for stability and to provided intentional gaps to receive poured concrete.

[0073] FIG. 20 depicts an elevational section view through a mid-wall portion of the middle floor planks 1201, taken through the line 20-20 of FIG. 19, after adding rebar members 2020 and/or longitudinal tension cables 1701 (depicted a dot, since the FIG. 20 shows a end-view of the cables 1701, perpendicular to the plane of the paper, as reinforcement). After placement of bar members 2020 and/or longitudinal tension cables 1701, and placement of forms 201 and/or 901, concrete would be poured into the intentional space between two middle floor planks 1201 to form a load-bearing integral beam 1203. Integral beam 1203 is similar to integral floor beam 1203 depicted in FIG. 17, but has a different configuration of the rebar members 2020 and/or cables 1701. FIG. 20 depicts the state of construction when the concrete has been poured over the planks 1201 form a floor or ceiling, as previously described in connection with FIG. 17, and prior to the bulbous longitudinal spaces 2010 between the planks 1201 being filled with concrete. As depicted in FIG. 20, when the concrete is poured, it fills the side-to-side gap between two of the planks 1201 to form the beam 1203.

[0074] Load-bearing beam 1203 includes longitudinal rebar or tension cable members 1701, like those depicted in FIG. 17. The rebar members 2020 or other reinforcement of beam 1203 is also configured with cup-shaped, internal bend rebar members 2020 that are perpendicular to longitudinal rebar or tension cable members 1701, and which are bent into an upwardly open cup-shape. It will be understood that the cup-shaped rebar elements are repeated longitudinally throughout the length of load-bearing beam, extending perpendicularly to the paper, as depicted.

[0075] The cup-shaped rebar members 2020 include upwardly extending rebar elements 2025 that have upper ends that terminate just below upper side of the planks 1201, and not so high that their upper ends will extend through the concrete topping 1705 forming the floor or ceiling.

[0076] Load-bearing beams 1203 can be positioned without a wall 1805 beneath them, as depicted in FIG. 20. In this case, a soffit form 1601 can be used, like that depicted in FIG. 16, which can be suspended from above using adjustable form ties 103 and/or snap ties 305, and/or by means of cables 1703 suspended from above. Cables 1703 can be suspended from an external structure or, for example, from a higher level, with rebar spanning the plank gap 1603, with tensioning devices 1703 suspended from a tensioning cable 1701 (which is depicted as a dot, since it extend longitudinally in the bulbous gap 2020, perpendicular to the paper. Where there is no higher level, however, as depicted in FIG. 20, the soffit form 1601 can be supported by struts 107, bracing, shoring, anchors, or combinations thereof, as depicted in FIG. 22. In either event, the soffit form 1601 should be held flush and tight against the underside of the planks 1201. (See FIG. 17).

[0077] Load bearing beams 1203 can also be positioned over any of the walls 1805, including the demising wall 1805 or side walls 1805, as depicted in, for example, FIG. 23. In this case, the walls 1805 themselves can assist with holding up the planks 1201, during initial placement of the planks 1201, while the concrete is poured into the gap to form the load-bearing beam 1701, at least until the concrete cures.

[0078] FIG. 21 depicts an elevational section view through a mid-wall portion of the middle floor planks 1201, taken through the line 21-21 of FIG. 19, after adding rebar and pouring concrete in the intentional space between the middle floor planks 1201 to form another embodiment of a load-bearing beam 1203, the concrete also being poured over the planks 1201 to form a floor or ceiling, as previously described.

[0079] As depicted in FIG. 21, in this embodiment, the load-bearing beam 1203 has rebar members formed into an elongated, upwardly open cup shape, similar to the rebar of FIG. 20. In the embodiment shown in FIG. 21, however, the load bearing beam has greater thickness in the vertical direction, including a portion extending above the surface of the floor or ceiling. This provides a higher-strength beam. Similar to the embodiment of FIG. 20, however, the upper ends of the upwardly-extending rebar members 2025 that extend near to the upper surface of beam 1203, do not extend so high that their upper ends will extend through the upper layer of concrete forming the beam 1203.

[0080] FIG. 22 depicts an elevational section view of the mid-wall portion of a demising wall 1805 on an upper level of an at least two level structure. The demising wall 1805 is positioned directly over a self-supporting cast-in-place load-bearing beam 1203, in the state it would be after concrete is poured into the opening between two planks 1201 but before curing. In this embodiment, beam 1203 has an inverted T-shape, with internal rebar 2020 bent into the shape of the outline of an inverted T-shape. The reinforcing steel also can include longitudinal tension cables 1701, which extend perpendicular to the plane of the paper, shown as dots.

[0081] Since, as depicted, the concrete would not yet be fully cured, a longitudinal cup-shaped soffit form 1601 supports the still-uncured concrete beam 1203. The soffit 1601, in turn, is supported by a strut 107, until the concrete has cured. When the concrete is cured, soffit 1601 and strut 107 can then be removed.

[0082] When the concrete is cured, the inverted T-shaped beam 1203 is stronger than the shapes of the beams 1203 and 1203 depicted in FIGS. 20 and 21, respectively. This enables, for example, placement of a demising wall 1805 on an upper level, where there is no wall below it on the immediately lower level. This provides great flexibility in configuring a desired building architecture.

[0083] FIG. 23 depicts an elevational section view of an exterior wall section 1805 for a lower level and an exterior wall section 1805 for an upper level, taken through taken through 23-23 of FIG. 19. Exterior wall sections 1805 and 1805 are vertically aligned, with a rebar and/or cable reinforced load bearing beam 1203 atop the upper edge of the uppermost panel 101 of wall section 1805 of the lower level and below the lower edge of the lowermost panel 101 of the wall section 1805 of the upper level. A portion of the inside gap is covered by the end of plank 1201. The remaining inner and outer open areas of the gap are covered by forms 201 or 901. When the forms are in place, concrete to be poured into an open upper portion of the gap. Until the concrete is cured, the end of the plank 1201 can be supported by a strut 107. It should be understood that beam 1203 can form an integral part of the perimeter ring beam that extends continuously around the building, supported by the uppermost panels 101 of all the exterior wall sections 1805 of the lower level.

[0084] FIG. 24 depicts an elevational section view of the mid-wall portion of a demising wall 1805 on a lower level of an at least two level structure, with another demising wall 1805 on the immediately higher upper level of the at least two level structure. As such, walls 1805 and 1805 are vertically aligned. The upper wall 1805 is supported by an inverted T-shaped cast-in-place beam 1203, like the inverted T-shaped beam in FIG. 22, and also has internal rebar 2020 bent into the shape of the outline of an inverted T-shape. The reinforcing steel also can include longitudinal tension cables 1701, shown as dots, which extend perpendicular to the plane of the paper. Prior to curing of the concrete, soffit form 1601 and an end of plant 1201 are supported by respective struts 107.

[0085] FIG. 25 depicts an elevational section view of the mid-wall portion of the generally middle demising wall 1805 of FIG. 18 of a lower level, but with the sets of floor planks 1201 on the left being aligned perpendicular to the paper, and the planks 1201 on the right of the figure being aligned orthogonally, i.e., parallel to the paper, generally as the planks 1201 are arranged in FIG. 19. A cast-in-place load supporting beam 1203 is disposed in the gap between the side of the plank 1201 to the left and the ends of the planks 1201 to the right, the gap at the bottom being closed by the upper edge of the uppermost panel 101 of the demising wall 1805, with struts 107 on either side of the demising wall 1805 supporting the proximate side and ends of the planks 1201 on either side of the wall, during construction and while the concrete cures.

[0086] FIG. 26 depicts an elevational section view of the mid-wall portion of a lower level demising wall 1805 and an upper demising wall 1805, vertically aligned with the lower demising wall 1805. In this embodiment, planks 1201 on both left and right sides are in alignment parallel to the plane of the paper and there is a cast-in-place beam 1203, similar to the beam 1203 depicted in FIG. 21.

[0087] The foregoing embodiments of FIGS. 18-26 show the great flexibility of configurations of building arrangements, for single and multi-level buildings made possible by the present invention.

[0088] Except to the extent of the distinctions specifically described for the embodiments of FIGS. 18-26, such as size and/or shape of parts, as compared to the embodiments of FIGS. 1-17, the construction and installation of the embodiments of FIGS. 19-26 can be the same as described for the embodiments of FIGS. 1-17.

[0089] Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.