Abstract:
Method of constructing a wall includes constructing a wall defining an upper region, a lower region, and a transition region between the upper and lower regions. The method includes erecting an exterior wall, the exterior wall including at least one layer, and the at least one layer including a wall segment having a height extending from the lower region to the transition region. The exterior wall segment may include a first material. Interior wall includes at least one layer, the at least one layer including a wall element having a height extending within the lower region. The interior wall element may include a second material. Method includes providing a non-post-tensioned reinforcing element in the lower region and providing a post-tensioned reinforcing element in the upper region of the wall.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a continuation of application no. PCT/US2004/007696, filed Mar. 30, 2004, which claims the priority of application Ser. No. 60/461,419, filed Apr. 10, 2003, and each of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The invention relates to walls and methods of constructing walls. More particularly, the invention relates to cast concrete walls, and even more particularly cast concrete walls including pre-cast exterior wall, and faced inner walls.  
       BACKGROUND OF THE INVENTION  
       [0003]     Walls have been built with and without the use of binders for hundreds of years.  
         [0004]     Cast concrete walls are likewise known that are constructed with or without the use of reinforcing elements, such as rebar.  
         [0005]     Concrete liquid containment vessels are known for use in the chemical, pulp, and paper industries.  
         [0006]     There are drawbacks of the known walls and vessels.  
       OBJECTS AND SUMMARY OF THE INVENTION  
       [0007]     It is an object of the invention to overcome the drawbacks of known walls and fluid containment vessels, such as liquid containment vessels.  
         [0008]     Another object of the invention is to provide a method of constructing a wall such as in the form of a vessel, which can be erected with little or no formwork.  
         [0009]     A further object of the invention is to provide a chemical-resistant liquid containment vessel which incorporates the economy of post-tensioned concrete with the flexibility and process adaptability of reinforced concrete.  
         [0010]     Another object of the invention is to provide a wall in which a faced inner wall, such as an inner wall having a chemical-resistant material incorporated substantially directly into the wall, may be provided.  
         [0011]     A still further object of the invention is to provide a method of constructing a wall, and a wall suited to post-construction changes in the wall, such by the addition of an opening in a lower portion of the wall.  
         [0012]     A further object of the invention is to provide a wall or vessel having a chemical-resistant inner wall constructed without compromising the structural integrity of the wall or vessel.  
         [0013]     Yet another object of the invention is to provide a method of constructing a wall, and a wall so constructed, that a chemical-resistant material for use as a face of the wall is incorporated into the wall during construction of the wall.  
         [0014]     Another object of the invention is to ensure that a chemical-resistant material used as a face or surface of the wall remains properly bonded with the wall in use.  
         [0015]     Yet another object of the invention is to provide a method of constructing a wall, and a wall so constructed, suitable for construction in a location having limited available space for construction formwork, such as in an existing industrial plant.  
         [0016]     A further object of the invention is to provide a wall and method of constructing such, that is environmentally friendly, more economical to construct than known walls, and readily adapted to the demands of different construction environments and different and end-use requirements.  
         [0017]     In summary, the method of constructing a wall according to the invention includes constructing a wall defining an upper region, a lower region, and a transition region between the upper and lower regions. The method includes erecting an exterior wall, the exterior wall including at least one layer, and the at least one layer including a wall segment having a height extending from the lower region to the transition region. The exterior wall segment may include a first material. Erecting an interior wall, the interior wall including at least one layer, the at least one layer including a wall element having a height extending within the lower region. The interior wall element may include a second material. Erecting the exterior wall at a distance from the interior wall, and providing a space between the interior and exterior walls. Providing a reinforcing element in the space between the interior and exterior walls in the lower region and providing a post-tensioning reinforcing element in the upper region of the wall. At least partially filling the space between the interior and exterior walls in the lower region of the walls with a cementitious material after the at least one layer of the interior wall has been erected.  
         [0018]     The inventive method and wall may include that the exterior wall is erected substantially without the use formwork, and the interior wall is erected substantially without the use of formwork.  
         [0019]     The inventive method of constructing a wall may likewise include that the interior wall defines an enclosed space.  
         [0020]     Relative terms such as left, right, up, down, interior, exterior, cementitious, wall, and the like are for convenience only and are not intended to be limiting. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0021]      FIG. 1  illustrates a partially broken away top perspective view of a wall according to an embodiment of the invention that has been formed to define an enclosed space defining a vessel, for example;  
         [0022]      FIG. 2  is a sectional view taken along line  2 - 2  of the wall of  FIG. 1 ;  
         [0023]      FIG. 3  is a sectional view of the wall of  FIG. 1 , taken along line  3 - 3  of  FIG. 1 ;  
         [0024]      FIG. 4  shows a portion of the wall of  FIG. 3  on an enlarged scale;  
         [0025]      FIG. 5  is a partially broken away sectional view of the wall of  FIG. 1  during construction; and  
         [0026]      FIG. 6  is a partially broken away sectional view of the wall of  FIG. 1  during construction. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]      FIGS. 1-6  illustrates an embodiment of a wall  10  according to the invention, and a method of making such a wall.  
         [0028]     Wall  10  may include an inner wall  14  and an outer wall  18 . A reinforcing wall  20  may be provided adjacent one or both of inner wall  14  and outer wall  18 . A reinforcing wall  20  may be provided between both inner wall  14  and outer wall  18 , and reinforcing wall  20  may be directly adjacent one or both of inner and outer walls  14  and  18 , depending on the intended use.  
         [0029]     A roof or cap  16  may be provided depending on the intended use.  
         [0030]     A reinforcing structure  24  may be provided adjacent inner and outer walls  14  and  18 , and may be between walls  14  and  18 .  
         [0031]     A cementitious material  28 , such as concrete or cement, may be used in forming reinforcing wall  20 .  
         [0032]     Reinforcing structure  24  may be adjacent to, or partially or completely encased by reinforcing wall  20 . Reinforcing structure  24  may include a variety of reinforcing elements, such as natural or synthetic aggregate, metal or plastic reinforcing fibers, metal reinforcing elements including rebar (reinforcing bar) typically made of steel and the like.  
         [0033]     Wall  10  may be reinforced substantially consistently throughout its height or width or both.  
         [0034]     Wall  10  may be substantially divided into an upper portion or region  30 , a lower portion or region  40 , and a middle or central region  50  disposed between the upper and lower regions  30  and  40 . Central region  50  may be termed a transition region between lower region  40  and upper region  30 , depending on the intended use.  
         [0035]     Reinforcing structure  24  may differ in upper portion  30  from the configuration of reinforcing structure  24  in lower region  40 . For example, one or more post-tensioned elements  60 , which may include one or more cables or elongated elements  62 , and one or more corresponding cable guides  64  may be provided in upper region  30 .  
         [0036]     Cable  62  may include one or more free ends  66  and  68 , such as shown in  FIG. 4 . A lock-off coupler  70  may be provided that receives, and fixes the free ends  66  and  68  relative to each other. For example, before, during, and after certain phases of construction of wall  10 , free ends  66  and  68  may be moved relative to each other in order to increase or decrease the tension in table  62 . Thanks to the use of cable guide  64 , which may be directly or indirectly attached to exterior wall  18 , when respective forces are applied to free ends  66  and  68  to increase the tension in cable  62 , increased force will be applied to cable guide  64  and, hence, to exterior wall  18 , thus compressing exterior wall  18 , as will be readily understood by a person having ordinary skill in the art. Then, after the desired tension in cable  62 , and compression of wall  18 , has been achieved, lock-off coupler  70  will be locked for securing free ends  66  and  68  in the desired position for maintaining the desired tension within exterior wall  18 .  
         [0037]     A housing  80  may be provided that is configured for receiving one or more lock-off couplers  70 , free end  66  and free end  68  of cable  62 .  
         [0038]     Housing  80  may include a left wall  84  and a right wall  86 , as shown in  FIG. 4 .  
         [0039]     Left wall  84  may be configured for mating with a free end  92  of an outer wall segment  90 . Right wall  86  may likewise be configured for mating with a corresponding free end  94  of wall segment  90 .  
         [0040]     Wall segment  90  may be one or more wall segments  90 , depending on the intended use.  
         [0041]     Exterior wall segments  90  may be made of a material such as pre-cast concrete.  
         [0042]     One or more lifting elements  98  may be provided in wall segment  90 , so that wall segment  90  may be raised into place. Lifting elements  98  may be attached to wall segment  90  during the forming of wall segment  90 , after the forming of wall segment  90 , or during the erection of wall  10 . The user or installer may use a piece of conventional lifting equipment for raising up and setting in place wall segment  90  during construction of the wall as will be readily appreciated.  
         [0043]     Inner wall  14  may include one or more layers or lifts  102 ,  104 , and  106  of bricks or tiles  112 .  
         [0044]     When erecting a first layer  102 , depending on the intended use, adjacent bricks or tiles  112  may be joined together by use of a mortar or adhesive  120 . Mortar  120 , when used, may be of a variety of materials depending on the intended use and the type of brick or tile  112  to be joined together. Further layers or lifts  104  and  106  may likewise be joined to previously laid layers by use of mortar  120 , again depending on the intended use.  
         [0045]     After one or more layers  102  and  104 , for example, have been laid, and mortar  120  has cured sufficiently, the cementitious material  28  forming reinforcing wall  20  may be provided between exterior wall  18  and interior wall  14 , such as by pouring an uncured concrete  28  into the space  130  defined between interior wall  14  and exterior wall  18 . The concrete  28  will be added up to a desired level, such as up to the height of an uppermost layer  106  of inner wall tiles, as shown in  FIG. 6 .  
         [0046]     The process of adding layers  102 ,  104 ,  106 , and so forth of tiles  112 , and mortar  120  as needed, allowing mortar  120  to cure, as needed, and making additional pours of concrete  28  will be continued to a desired height.  
         [0047]     At least a part of one or both of exterior wall  18  and interior wall  14  may be supported by formwork placed on one or both of the inside or outside of respective exterior and interior walls  18  and  14 .  
         [0048]     In installation locations where little working space is available outside of, namely outwardly of the exterior of exterior wall  18 , thanks to the configuration of wall segment  90  with its optional configured free ends  92  and  94 , wall  10  may be erected without the use of exterior formwork on the outside of exterior wall  18 .  
         [0049]     Post-tensioned element  60  likewise may be used to ensure that wall segments  90 , as needed, are sufficiently securely held in place during construction of wall  10 , whether or not configured free ends  92  and  94  are provided, so that exterior formwork is not needed. After the desired number of layers or lifts  102 ,  104 ,  106 , and so forth of tiles  112  have been laid, and after cable  62  has been sufficiently post-tensioned after a sufficiently long curing time of concrete  28 , then interior  88  of housing  80  may be filled in with a cementitious material. To assist during the filling in of interior  88 , bricks or tiles may be used to form or close an open face  144  of housing  80 .  
         [0050]     In the case where wall  10  is to be built as a vessel for retaining a fluid such as liquid, the user may wish to provide one or more openings in wall  10  for accessing a liquid contained therein in use.  
         [0051]     Thanks to the use of lower reinforcing structure  170  in lower portion  40 , an opening  150  may be provided during the initial construction of the interior wall  14 , such as prior to the pouring of concrete  28  around a nozzle  160 . Alternatively, after construction of lower portion  40 , for example, hole  150  may be provided, such as by drilling through exterior wall  18 , cured concrete  28 , and interior wall  14 . A nozzle  160  may then be inserted. Nozzle  160  may be secured in place by conventional means, or in the case where nozzle  160  is made of a weldable material, which material may be welded to lower reinforcing structure  170 , nozzle  160  may be directly physically secured to lower reinforcing structure  170 . Thanks to the use of horizontal and vertical rebar array  172  and  173  in lower portion  40 , nozzle  160  may be installed without degrading the integrity of lower reinforcing structure  170 , even if a part of lower reinforcing structure  170  is removed when forming hole  150 .  
         [0052]     If desired, the user may install one or more reinforcing elements  172  and  174 , such as pieces of rebar, which may be welded together in a manner so as to restrict movement of nozzle  160  out of its desired orientation during pouring of concrete  28 . Thus, one or more reinforcing elements  172 ,  174  may be secured to one or more portions of lower reinforcing structure  170 , such as by wiring or tack welding reinforcing element  172  to lower reinforcing structure  170 . A harness or array of reinforcing elements may constitute reinforcing element  172  to restrict movement of nozzle  160 .  
         [0053]     Depending on the intended use, a slab or foundation  200  may be provided on which wall  10  is erected.  
         [0054]     One or more holes  210  may be provided in foundation  200 , such holes  210  being sized to receive a lower free end of vertical reinforcing element  171 , for example. A securing element, such as a dowel, may be provided between a side of hole  210  and vertical reinforcing element  171 .  
         [0055]     It will be appreciated that various components may be made of synthetic materials, including plastics, metal, including but not limited to steel, cast iron, aluminum, and other appropriate metals depending on the intended use.  
         [0056]     Appropriate sealants for ensuring fluid-tight connections may be used at appropriate joints and interfaces between different elements of wall  10 , as well as between wall  10  and its surroundings. For example, at an interface between wall  10  and foundation  200 .  
         [0057]     The bricks or tiles used as the interior wall may be chemical-resistant materials such as chemical-resistant SEMCO™ (Stebbins Engineering and Manufacturing Co., Watertown, N.Y.), or a SEMCO™ 10% acid-resistant brick coupled with a 90% SEMPLATE™ tile (for example, a STEBBINS of Watertown, N.Y., salt-glazed vitrified tile). The tiles may be any desired dimension, such as nine inch by nine inch (9″×9″) or nine inch by twelve inch (9″×12″) tile, the tile dimensions being larger or smaller depending on the intended use.  
         [0058]     While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto.