Building system and method of constructing a multi-walled structure

A building system including a plurality of supports structured to be vertically disposed in an underlying surface in spaced apart relation from one another, and a plurality of support headers removably disposed on an exposed end of each of the supports. Each support header includes a mounting hub that removably engages the exposed end of the support, and a plurality of engagement elements. A span element is further provided and extends between adjacent supports, each span element including a lock element that matingly engages a corresponding engagement element at the supports so as to removably secure the span element in position. A re-enforcement panel formed of a stiff, open grid configuration is suspended from the span element along with an application panels. The application panel includes a plurality of apertures defined therein to define an open mesh, and a quantity of un-hardened concrete is applied to the application panel in order to substantially cover the application panel, the re-enforcement panel and the supports, thereby defining a wall upon hardening.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a building system and method for constructing a multi walled structure, configured to rapidly construct a multi walled structure at almost any location, in a manner which achieves strong, rigid walls, having identifiable strength quotients so as to permit the construction of regulated building structures and the appropriate incorporation thereof into engineering and architectural plans. Moreover, the present building system and method is substantially economical to utilize and incorporates a plurality of reusable, easy to transport and manipulate components, while benefitting from direct concrete application techniques that can be achieve quickly and at low cost in the field.

2. Description of the Related Art

The construction of economic and/or affordable housing and/or other building structures is of paramount importance in virtually every society. Unfortunately, however, of equal importance is the endurance that all building structures are fabricated to certain minimum standards and specifications so as to provide a safe dwelling and/or other facility which can withstand multiple loads and stresses, such as from the elements, acts of nature, normal wear and tear and/or construction stresses.

Although a large number of building structures are still formed from steel and/or wood framing, with the inclusion of cinder blocks and/or molded, poured concrete elements, those traditional manufacturing techniques are often expensive, time consuming and may not be practical in a variety of circumstances and/or at a variety of locations. Indeed, it is recognized that based on the ever increasing cost of construction, many building structures are often formed in what may be considered a pre-fabricated and/or modular type of manner. For example, large wall slabs are often precast at an appropriate, remote location, and those precast slabs are transported to the construction site and appropriately erected, as needed, by various types of machinery. As a result, a relatively strong building structures can be defined in a somewhat rapid and cost effective manner. Regrettably, however even such manufacturing techniques can often prove costly in certain circumstances, and are typically only practical when forming large facilities, wherein heavy duty framing can be installed, and more importantly wherein large heavy duty equipment can have access so as to appropriately position the preformed slabs. As a result, a large segment of the construction field, such as in remote and/or harder to reach locations and/or in connection with smaller facilities and tighter budgets, cannot truly benefit from such pre-fabricated building techniques.

To this end, others in the art have strived to define a variety of different, low cost and economical manners in which to construct building structures. In particular, such techniques seek to deviate from traditional uses of brick and mortar, and/or cinder blocks, etc. so as to define a wall structure, and typically require large amounts of manual labor. One such technique that has recently developed incorporates the application of concrete, such as by a pressurized spray, to a mesh, thereby defining an appropriate wall. While substantial benefits have been derived from such techniques, a large room for improvement still remains. For example, existing construction systems of this type are often difficult and/or complicated to set up, and require extensive and expensive framing materials to be positioned and define portions of the finished wall. Furthermore, such traditional techniques often rely on a flimsy mesh panels to which applied concrete may adhere, but do not truly provide a significant degree of strength and/or re-enforcement to the wall structure, let alone verifiable strength and tolerances figures for one wall as compared to another wall manufactured utilizing the same technique. As a result, it would be highly beneficial to provide a building system and method which can be quickly and easily set up for the appropriate application of concrete and which provides properly defined and uniformly formed walls in an economical and minimally labor intensive manner. Moreover, it would be beneficial for such a technique to provide uniform and readily identifiable re-enforcement and strength characteristics to the wall structure, thereby providing a strong and durable wall with consistent strength characteristics throughout an entire construction. Also, such a system should not be limited to a formation of straight wall segment, but should be able to achieve appropriately positioned corner elements, including interior and exterior corner elements extending in two or more different directions.

SUMMARY OF THE INVENTION

The present invention relates to a building system which is preferably utilized for the construction of a multi walled facility. Specifically, the building system includes at least two, but typically a plurality of supports. The supports are structured to be vertically disposed in an underlying surface in spaced apart relation from one another, and appropriately secured in place.

A support header is further provided. In particular, a support header is structured to be removably disposed on an exposed end of each of the supports that have been previously disposed in the underlying support surface. Preferably, the support headers each include a mounting hub that removably engages the exposed end of the support, such that after construction of a wall section and/or the entire structure, the support header can be substantially easily removed from its engaged relation with the support, and re-used at a subsequent location.

The support headers of the present invention further include at least one, but typically two or more engagement elements. The engagement elements are specifically structured and disposed so as to effectively engage and retain a span element. Specifically, a plurality of span elements are preferably provided, each span element structured to extend between adjacent ones of the supports, and including a corresponding lock element. The lock elements, which are preferably disposed at least at opposite ends of each span element, matingly engage the engagement elements on the corresponding support headers of adjacent supports. Moreover, the lock elements of the span elements and the engagement elements of the support headers preferably removably engage one another, thereby achieving effective and appropriate aligned positioning of the span elements between the adjacent supports, but also allowing for appropriate removability of not only the support headers, but also the span elements for subsequent reuse.

Suspended from each of the span elements is a re-enforcement panel. The re-enforcement panel is generally stiff and includes an at least partially open configuration. Furthermore, an application panel is also provided and is structured to be suspended from the span element in generally confronting relation to the re-enforcement panel. The application panel preferably includes a plurality of apertures defined therein and is structured to receive a quantity of concrete thereon. In particular, a plurality of un-hardened concrete is structured to be applied, either manually and/or through mechanical means to the surface of the application panel in order to substantially cover the application panel, the re-enforcement panel and the supports, and thereby define a wall upon hardening.

Preferably utilizing a preceding system, the present invention further relates to a method for constructing a multi walled structure. In a preferred embodiment, the method comprises the opening and/or defining of at least three holes in an underlying surface and the securement of a rigid support in a vertical orientation within each of those holes. A support header can then be placed on the exposed end of each of the rigid supports, and a span element is appropriately positioned to span adjacent ones of the rigid supports, engaging the correspondingly positioned support headers. A header cap is then positioned in an engaging relation with the adjacent span elements, as well as the support header, which they both correspondingly engage, thereby effectively maintaining a secure positioning and alignment of the span elements relative to one another.

With the span element in place, at least one application panel is suspended from each of the span elements, and a pair of re-enforcement panels are further suspended from each of the span elements in sandwiching relation to the application panel. With all of the panels in place, a quantity of concrete is then applied to at least the application panels, the concrete being applied from the underlying surface up to the span element so as to effectively cover the application panels, the re-enforcement panels and the rigid support. The concrete is then allowed to harden so as to define a wall, and finally, the header caps, span elements and support headers are effectively removed from the formed wall for subsequent re-use as needed.

These and other features and advantages of the present invention will become more clear when the drawings as well as the detailed description are taken into consideration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Shown throughout the Figures, the present invention is directed towards a building system, generally indicated as10. In particular, the building system10is structured to be substantially rapid and easy to implement in a cost effective manner so as to form a preferably multi walled structure which has substantial strength and durability despite its low cost and rapid deployment. Furthermore, the present building system10is specially structured to facilitate rapid and easy construction in a variety of locations including locations wherein heavy equipment cannot necessarily be utilized.

As illustrated in the Figures, the present building system10includes at least two, but often a plurality of supports20. The supports20are preferably substantially rigid, and may be formed from any variety of strong, durable rigid materials, but preferably iron or steel. Moreover, the thickness and/or dimensions of the supports may correspondingly vary, however, a standard ¾ inch to 1 inch diameter may be sufficient in a majority of cases, and to this end, and in order to maximize the economics of the overall construction, standard and/or conventionally available materials, such as re-bar type rods are preferably utilized.

The supports20are structured to be vertically disposed into an underlying surface25in spaced apart relation from one another, and are preferably effectively and substantially permanently secured into the underlying support surface25in a vertical, upstanding orientation. To this end, the overall height of these supports20may vary depending upon the desired height of the wall section to be formed above the underlying surface25. Furthermore, the underlying surface25may be dirt or soil, or may be concrete or any other material which may make a foundation or even an underlying base for a subsequent foundation of a building structure. As a result, it may be preferred that a hole24be made in the underlying surface25into which the support20can be inserted, and then subsequently secured, such as by pouring concrete into the hole24and thereby fixing the support20in place.

Looking further to the number of supports20which may be utilized, for purposes of clarity when reference is made herein to the present invention, a wall section may be defined as the section between a pair of spaced apart, yet adjacent supports20. Nevertheless, it is recognized that more than two supports may be utilized to define a single wall section of larger or smaller size, and the beginning and/or ending of a wall section need not necessarily be determined by a change in direction of that wall section. As indicated, however, for purposes of clarity a wall section may be defined between an adjacent pair of supports20.

The building system10of the present invention further includes at least one, but typically a plurality of support headers30,30′. In particular, the support headers30,30′ are structured to be removably disposed on an exposed end22of each of the supports20. Furthermore, as will be described in greater detail subsequently, the support headers may include a standard linear support header30, as illustrated in FIG.1and/or a corner support header30′ as illustrated in FIG.2. Looking in further detail, however, to the positioning of the support headers30,30′ on the supports, each preferably includes a mounting hub32that removably engages the exposed end22of the support20. In this regard, the mounting hub32may include any of a variety of configurations and/or structures which provide for effective securement and positioning of the support header30,30′ on the exposed end22of the support20. In the preferred embodiment, the securement to the support20is removable and moreover, in the illustrated embodiment the mounting hub32preferably includes a socket into which the exposed end22of the support20may be effectively introduced, such as in an axial manner. As a result, the support header30,30′ can be effectively fitted over the end of the support20, with the support20effectively secured in the underlying surface25, in order to achieve an appropriate vertical structure that preferably stands on its own.

As indicated, the support header30,30′ is preferably removable subsequent to formation of the wall, as will be described. As such, it is preferred that the mount hub32, and in particular the socket configuration include a rounded exterior surface. In this manner, even when encased in concrete, a twisting of the support header30,30′, such as with the aid of some force or an impact, can effectively disengage the mount hub32from an embedded orientation within the concrete of the formed wall section, providing for removal from the support20. In such an embodiment, the resultant hole may be filed with small quantities of concrete in order to seal the opening and further define the wall section. Additionally, preferably disposed within the socket of the mounting hub32is a spacer element34. In particular, the spacer element34is preferably secured to the support header30,30′ and helps to achieve some spacing of the support header30,30′ above the end of the support20.

In addition to the mounting hub32, each support header30,30′ also preferably includes one or more engagement elements36. In particular, in the preferred embodiment of the support headers30,30′ may include a frame member35that is preferably positioned atop the mounting hub32so as to generally define a platform. Disposed preferably at that vertical platform35are one or more of the engagement elements36. Specifically, the engagement elements36are each structured to effectively and securely engage a span element40further included as part of the present building system10. Preferably, the present building system10includes one or more span elements40. These span elements40are preferably formed from a substantially strong, rigid material construction, and may include a hollow and/or solid tubular configuration. Furthermore, the span elements40are preferably structured to extend from one support20to an adjacent support. In this regard, it is recognized that a single span element40may extend between a plurality of supports20, however for purposes of clarity and explanation a description relative to the spanning of only a pair of spaced apart supports20will be described. Furthermore, in the preferred, illustrated embodiment, the span element may include a rectangular cross section such that changing the orientation of the span element40may change a thickness of the wall to be produced in the manner described. For example, the span element may have a 3 inch by 4 inch dimension so as to allow for a 3 inch or 4 inch wall thickness guide to be defined.

In order to effectively secure and position the span elements40in spanning relation between adjacent supports20, each span element preferably includes at least one lock element42, and typically at least one lock element42disposed at opposite ends thereof. These lock elements42are preferably, but not necessarily, in the form of apertures and are structured to engage the engagement elements36on the support headers30,30′ in order to achieve effective interlocking, yet removable engagement therebetween. Looking to the preferred, illustrated embodiments of the present invention, the engagement elements36of the support headers30,30′ preferably include rigid shaft segments which extend upwardly from the platform35of the support headers30,30′. Correspondingly, the lock elements42of the span elements40are preferably defined by correspondingly disposed apertures which are structured to be fitted over the engagement elements36so as to achieve effective interlocking engagement therebetween. Furthermore, in the illustrated embodiment, the apertures may be defined in all faces of the span element40so as to allow for alternate positioning of the span element. It is also recognized that although such a configuration of the engagement element and lock element is preferred, alternate configurations may also be equivalently utilized to achieve interlocking, including the inclusion of a rigid shaft segment depending from the span element40into a corresponding aperture and/or recess associated with the support header30,30′. Nevertheless, viewing the preferred, illustrated embodiment preferably an aperture42is defined at each end of the span element40to engage one of the engagement elements36on each corresponding support header30,30′ thereby effectively providing for interlocking therebetween. Furthermore, although it is recognized that a pair of engagement elements36may be provided to engage each end of a single span element40, thereby prevent twisting and/or pivoting therebetween, in the illustrated embodiment and as will be described subsequently, only a single engagement element36and lock element42need engage one another to provide for effective securement. As a result of this configuration, and as illustrated inFIG. 1, the span elements40may be effectively disposed in an end relation to one another, wherein a pair of span elements40engage a single support header30in a linear and/or slightly angled configuration.

TurningFIG. 2, however, and as previously recited, it is also understood that the support header30may further include a corner support header30′. In such an embodiment, the engagement elements36may be slightly off set from one another and may be positioned so as to allow span elements40to extend from the corner support header30′ in different directions from one another, and in many embodiments at generally a 90 degree angle relative to one another. In this regard, although it is preferred that at least two engagement elements36be provided on the corner support header30′ as with the other embodiments of the support header30, it is also noted that in such an embodiment a larger number of engagement elements, such as three or four engagement elements may be effectively provided at the corner support header30′. As such, the span elements40may extend away from the corner support header30′ in virtually any direction, including making a four corner type wall section, and/or merely making a 90 degree wall corner that may go in any direction.

Utilizing the preferred structure of the engagement elements36and lock elements42between the support headers30,30′ and the span elements40, it is recognized adjacent span elements40secured at the same support header30,30′ may be pivoted at virtually any angle relative to one another. While the securement of the opposite ends of the span element40at the support header30,30′ on an adjacent support20will effectively serve to define a relative angle and/or orientation of adjacent span elements40to one another, in the preferred, illustrated embodiments a corresponding header cap50,50′ is preferably provided for each support header30,30′. In particular, the header cap50,50′ is preferably structured to engage each of the two or more adjacently disposed span elements40at the support header30,30′, as well as to effectively engage the support header30,30′ itself. In that manner the relative orientation of the adjacent span elements40can be effectively secured and a substantial degree of stability can be maintained while the construction process is completed. Looking toFIG. 1, the header cap50may include a linear header cap such as in the form of adjacent, and end to end wall section, or as illustrated inFIG. 2may include a corner header cap50′ which can appropriately secure and maintain the adjacent span elements40in a desired angled orientation relative to one another. Although a variety of different modes of engagement may be effectively achieved between the header cap50,50′ and the span elements40and support headers30,30′, with regard to the preferred, illustrated embodiments of the engagement elements36and lock elements42, it is preferred that the header caps50,50′ be configured with at least one but preferably a pair of apertures54as well as a pair of downwardly depending shaft segments52. Specifically, the apertures54on the header cap50,50′ are preferably structured to receive the distal ends of the engagement elements36of the support header30,30′ subsequent to their passage through the lock element42of the span elements40. Additionally, however, each of the span elements40preferably also includes an additional pair of apertures42′ spaced apart from the lock elements42. This additional set of apertures42′ is preferably configured so as to receive the downwardly depending shaft segments52of the header caps50,50′ therethrough. As a result, an effective and sturdy securement of adjacent span elements40relative to one another can be appropriately achieved in a substantially quick and rapid manner, once the concrete footer at the base of each support20has hardened.

Preferably suspended from each of the span elements40are one or more panels. In particular, in the preferred, illustrated embodiments one or more re-enforcement panel(s)60are preferably secured in a suspended orientation beneath the span element40. Each re-enforcement panel60preferably includes an at least partially open configuration and is formed of a strong, generally stiff material. For example, an open mesh or grid of rigid metal strands or fibers may be appropriate, and in a preferred embodiment 6×6, no. 10 road grade mesh may be preferred. Of course, it is recognized that the re-enforcement panel60may be formed of a variety of materials, however, a metal is preferred for strength and/or durability, and a standard gage is preferred so that readily identifiable strength characteristics can be associated to its re-enforcement of the wall section. Moreover, when multiple re-enforcement panels60are used, they are preferably offset from one another such that the openings defined therein are not necessarily lined up exactly. Furthermore, each re-enforcement panel60, which as indicated is suspended from the span elements40, may be secured in any of a variety of fashions including hooks, latches, magnets, clips, etc. In the illustrated embodiments a roofing strap or a series of wire loops64are provided for quick and easy looped fastening about the span element40.

Further suspended beneath each span element40is preferably at least one application panel62. Specifically, the application panel62preferably includes a plurality of apertures defined therein, and may also be formed of a mesh type configuration, such as from an expanded metal that may be smooth or contoured. In this regard, it may be preferred that the construction of the application panel62be such that the apertures defined therein be somewhat closely spaced relative to one another. In particular, the present invention further comprises a quantity of unhardened concrete70which is to be applied at the application panels62in order to ultimately define the wall. As a result, by including an open configuration with preferably somewhat small, tightly spaced apertures, effective application of the concrete can be achieved. Further, a re-enforcement panel60may preferably be disposed on opposite sides of the application panel62, and the quantity of concrete70is preferably applied from both sides in order to define a wall segment.

Although manual application of the unhardened concrete may be effectively achieved, in the preferred embodiment a pressurized application of unhardened concrete in a spray type fashion is preferred. Based upon a structure and configuration of the application panels62and the re-enforcement panel60, however, quantities of concrete can pass therethrough, yet still substantially adhere, at least to the application panels62, so as to give thickness to the wall segment and provide for a substantially solid layer of concrete70throughout. As mentioned, once the concrete70has been applied from one side, if necessary, a further quantity of concrete can be applied from an opposite side in a similar fashion so as to appropriately define the wall segment. Moreover, if desired, once the concrete is applied, smoothing can be achieved by a user, such as using a trowel or similar type of smoothing process. Nevertheless, in the preferred embodiment the unhardened concrete is preferably applied to extend from the underlying surface25up to at least a top of the panels60,62and/or up to the span element40. It is, however, preferred that the span element40not be completely covered in order to permit its subsequent removability.

In order to achieve a substantial degree of uniformity as to the thickness of the wall segment that is defined utilizing the building system10and method of the present invention, each corner support header30′ preferably includes one or a plurality of guide segments80defined therein. In particular, the guide segments may include one or a series of single or multi-sized notches. Although a single guide segment80may be sufficient, in the preferred embodiment, the corner support header30′ preferably includes a guide segment80on all faces thereof so as to facilitate usage of a specific corner support header30′ at generally any corner of a building structure to be defined. The guide segments80are structured to engage and maintain a vertical guide locator82appropriately vertically aligned. The vertical guide locator82preferably includes a substantially rigid segment which in the illustrated embodiments may include a section of the span element40and/or a piece of lumber, such as a standard 2×4. With the vertical guide locator82appropriately secured in the desired vertical orientation, one or more guide elements84,84′ are preferably extended therefrom to a correspondingly disposed vertical guide locator82on an adjacent support header30,30′. In particular, the guide element84,84′ may include a long strand of wire, string or other material and extends from a vertical face of the vertical guide locator82to a corresponding vertical face of the vertical guide locator on an adjacent support header30,30′. In the case of the inclusion of a pair of guide elements84,84′, they may extend from opposite sides of the vertical guide locator82such that the width of the vertical guide locator82will generally define a width of the wall structure that is ultimately formed. Of course, it is recognized that the guide element84,84′ may include a single element wrapped around one or more of the vertical guide locators82or may include separate segments. Further, the guide elements84,84′ may be directly adjacent the vertical side faces of the vertical guide locator82or may be spaced therefrom, such as through the use of a nail, clip, screw, etc., which provide a defined spacing from those side faces. With the guide element84,84′ in place, an appropriate width of the wall structure can be defined subsequent to application of the unhardened concrete, with the guide elements84,84′ serving as a markers for the desired thickness of the wall structure, indicating how much of the concrete should be applied and/or how much of the concrete should be removed during a smoothing process. Indeed, it is also noted that while a single guide element84or84′ may be disposed on each side of the wall section, a series of vertically spaced guide elements84,84′ may also be provided so as to provide an even greater degree of uniformity relative to the thickness of the finished wall section along its entire height.

In addition to the proceeding structural features, it is also recognized that a variety of construction features which may be beneficial for the formation of the building structure may also be effectively integrated into the building system10of the present invention. For example, one or more roofing straps47may be effectively secured, such as to one or more of the panels60,62, thereby appropriately being embedded in the hardened concrete. In such an embodiment, the roofing straps47may merely protrude out from beside the span elements40, and/or one or more slots46may be defined in the span element40for appropriate passage of the roofing straps47therethrough, if necessary. Additionally, as illustrated inFIG. 1, in addition to or instead of the wire loops64, the one or more panels may be suspended from the span elements using the roofing straps47. Specifically, a series of spaced, and often precisely spaced and sized slots46may be defined in the span element40, a corresponding roofing strap47being extended there through. With the strap47preferably suspended in place at a uniform height, such as by passing a segment through one of its nail holes and allowing it to hang in place, an end of the strap47can include or be formed into a hook onto which the panels are suspended at a uniform height. Furthermore, in this and other embodiment a horizontal segment of re-bar type re-enforcement can be suspended with the panels to provide added re-enforcement.

Furthermore, one or more forms and/or molds may also be suspended from the span elements40so as to define windows, doors and/or other openings. In particular, a panel60,62may be cut, and a removable form appropriately suspended and/or disposed at a desired location for a window opening as defined by the cut. As such, once the concrete has effectively hardened around the form, the form must merely be removed and the window opening or other opening remains. Of course, it is also understood that an appropriate form may be positioned merely over a panel60,62, such as using the same structured used to define the span elements40, and once the form is removed after at least partial hardening of the concrete, cutting of the panels in order to fully define the opening can be achieved.

Also, although the present structure and configuration of the various components of the present building system10are such that removability of the header caps50,50′, span elements40, and support headers30,30′ should be relatively easily achieved after at least partial and preferably complete hardening of the concrete to define the wall section, in some instances a lubricant type material and/or other material which prevents the concrete from hardening and/or excessively sticking thereto may also be applied to those removable elements.

From the proceeding it can also be seen that the present building system10is especially beneficial for use during the employment of a method of constructing a multi walled structure. Specifically, the method may include the opening of at least three, but generally a large number of holes in an underlying surface25, and then vertically securing a rigid support20in each of the holes. A support header30,30′ having at least two engagement elements36is then disposed on the exposed end22of each of the rigid supports20and a span element40is suspended between the adjacent support20at the support headers30,30′. With the span element(s)40in place, a header cap50,50′ is preferably disposed thereon so as to effectively secure adjacent span elements40in an appropriately aligned configuration relative to one another, and a plurality of panels, including preferably a re-enforcement panel60and an application panel62are suspended from the span element40. Finally, a quantity of concrete is applied to the panels and allowed to hardened, after which the header caps, span elements and support headers may be removed for re-use as needed.

Now that the invention has been described,