Modular concrete storage structure

A series of pre-fabricated building components assembled into modular units and further assembled into circular storage structures of various heights.

Not Applicable

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

Not Applicable

STATEMENT REGARDING PRIOR DISCLOSURES BY AN INVENTOR OR JOINT INVENTOR

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates to storage structures and, more particularly, to storage structures made from pre-cast or pre-stressed concrete components.

Since ancient times, various storage structures have been employed. For example, for decades, if not centuries, silos have been used for the storage of corn and other grains. Silos have also been used to store silage, manure intended to be used as fertilizer, and other agricultural products. For at least the last one hundred years, there has been an increased demand for a low-cost durable silo structure. Various manufacturing methods have been employed for making silos, but these methods have not resulted in any substantial reduction in the cost of materials, labor to complete construction of the silo or in any significant advantages with respect to ease of construction. To this day, there continues to be a need for silos that are sufficiently strong to withstand the elements, inexpensive to manufacture, less laborious to manufacture, quicker to assemble on site, primarily assembled at ground level, and simple to build, move, disassemble and rebuild when desired.

Ideally, most of the components of the silo should be built in a controlled environment such as a factory to maintain better working conditions, better quality control and more consistent production to specifications. Likewise, the components should be adapted to be assembled using a crane to eliminate manual handling of components at considerable heights. Ideally, the number of components that must be assembled at the assembly site should be limited in number and in type to simplify assembly and the time required to complete the assembly.

Not Applicable

BRIEF SUMMARY OF THE INVENTION

The invention comprises a series of pre-cast concrete wall panels configured to be attached to each other forming a hollow circular segment of a storage structure. Edges (top, bottom, and side) of the panels are configured with tongue and groove features to help align and interlock panels with adjacent panels. The outer surface is configured with features to secure one or more hoops passing around the outer circumference of the circular segment. Each circular segment is modular and movable once assembled. A series of circular segments are stacked one on other, preferably using a crane, forming the wall of a concrete storage structure. Seams in adjacent circular segments are preferably offset for additional strength. Adhesive is preferably applied to the tongue and/or groove features before they are assembled to provide additional strength and sealing.

The invention further comprises a series of pre-cast concrete panels configured to be attached to each other forming a round convex storage structure roof. Edges of the panels are configured with tongue and groove features to help align and interlock panels with adjacent panels. The round storage structure roof is modular and movable once assembled.

DETAILED DESCRIPTION OF THE INVENTION

This description of the preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “connected”, “connecting”, “attached”, “attaching”, “join” and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece, unless expressively described otherwise. Further, for the purposes of this application, including claims, where not otherwise indicated, plurality means at least one.

The storage structure1of the present invention is a generally cylindrical structure. Component pieces of the structure are preferably made off-site, transported to the installation location, and assembled. The component pieces are preferably made of pre-cast/pre-stressed concrete. The component pieces may contain re-bar, wire mesh, fiberglass strands, or other strengthening materials. When strengthening components containing metals are contained in the component pieces, the strengthening components are preferably encapsulated in the concrete to reduce corrosion.

The walls of the storage structure1are preferably generally cylindrical. Component wall pieces4therefore preferably have interior faces19which form the arc of a circle. When a plurality of component wall pieces4are connected end-to-end, they form the wall section of a cylinder40, having an open top and bottom. This wall section of a cylinder40may be called a course. The top, bottom, left, and right edges of the component pieces are preferably configured with cooperating tongue and groove features. For example, if the top of a component wall piece is configured with tongue features19, the bottom is preferably configured with groove features17so the tongue features40of one course40fit into groove features17of the next higher course40. In a preferred embodiment, the top of component wall pieces4are configured with tongue features19and the bottom of component wall pieces4are configured with groove features17, though top and bottom cooperating features may be reversed without deviating from the present invention. By way of further example, if the left edge of a component wall piece4is configured with tongue features23, the right edge of a component wall piece4is configured with groove features21so the tongue features23of component wall piece fit4into groove features21of the adjacent wall component piece4.

In a preferred embodiment, after or as the component wall pieces4are assembled into a course40, the component wall pieces4of the course40may be further secured by a band130. In a preferred embodiment, at least some component wall pieces4are therefore further configured with features122by which one or more bands130may cooperatively interact with the component wall pieces4. The band(s)130of one course (e.g.40d) are separate from, and not connected to, the band(s)130of adjacent courses (e.g.40cand40e) thereby making each course40a self-contained unit. In a preferred embodiment, each band130is attached to itself (seeFIGS. 20 and 21). In an alternative embodiment, the ends of each band are attached to a feature on a component wall piece.

The number of bands130on a course40may vary based on the location of the course40in the storage structure1. For example, a bottom course40in a storage structure1may have 7 bands130. A course40mid-way up the storage structure1may have 4 bands. A course40near the top of the storage structure1may have 1 band130.

The component wall pieces4are preferably configured having a thickness which is less at the center and greater at the edges. The thickness of the component wall pieces4at the center is selected to provide the desired amount of crush resistance and resistance to outward forces when the storage structure1is filled. The edges of the component wall pieces4is preferably selected such that the tongue and groove features have sufficient height, depth, and thickness to aid in alignment when component wall pieces4are assembled, sufficient surface area for adhesive to adhere, and resist sheering between adjacent component wall pieces4. The dimensions of the tongue and groove features may also be selected to achieve the desired of fit between component wall pieces4when a seal is placed between component wall pieces4.

The roof70of the storage structure1is preferably comprised, at least in part, of pre-cast/pre-stressed concrete panels. The bottom edges78of roof panels71,72,73are preferably configured to rest on the top of the top course40of wall panels and are preferably configured with features configured to interact with features on top of the top course40of wall panels. In a preferred embodiment, the bottom edges78of the roof panels71,72,73are configured with grooves79configured to interact with tongue features19of the top course. In a preferred embodiment, internal edges74,76,80,82of roof panels are configured with cooperative tongue75,77and groove81,83features. In a preferred embodiment, some component roof panels have the shape of a truncated sector. At least one component roof panel then is then preferably circular configured to close the opening left by the truncated section of other component roof panels.

Component wall and ceiling pieces4are preferably manufactured at a facility where the quality can be strictly controlled and the concrete can be tested. Component wall pieces are then shipped to the location where the storage structure1is to be constructed. The storage structure1of the present invention is built by placing a pad60at the location2where the storage structure1is desired. In an alternative embodiment, a structure, such as a drive-through loading/unloading structure, or other receptacle for the In a preferred embodiment, features configured to interact with features of the bottom course40are preferably formed into, or attached to, the pad. Appropriate anchors or foundations60may be installed on/under the pad. Component wall pieces4are assembled as course40(seeFIG. 4). If desired, adhesive and/or seals are placed between adjacent component wall pieces4as they are assembled to provide the desired strength and/or sealing properties. One or more bands130are placed around the course40. The process is then repeated for subsequent courses. Each course40is preferably assembled at or near ground level before courses40are stacked one on another. Similarly, the component pieces of the roof panels are preferably assembled to form the roof.

Once the desired number of courses40(selected based upon the desired height) of the storage structure1) and roof70are assembled, further assembly of the storage structure1is ready to commence. A crane is preferably brought to the site. Any necessary adhesive or seal is placed on the pad60where the bottom course40awill be placed. Any necessary adhesive or seal is placed on the top of the course40abefore it is placed. The crane is then used to lift the course40aand place the course40aon the pad60. Any necessary adhesive or seal is placed on the top of subsequent courses40b,40c,40d, etc. before it is placed to maximize safety by performing as much work as possible close to the ground. A man-lift, ladder, or other means may be used to elevate workers to the level necessary to align courses as they are stacked. Once all desired courses40are stacked forming the wall of the storage structures1, the roof70is placed on top of the top course40. If desired, a coating may be applied to the interior of the walls and/or roof70to provide desired characteristics including, but not limited to, lubricity, permeability, et. al. characteristics. In this manner, a relatively large storage structure1may be installed in a relatively short time.

At a later date, the capacity of the storage structure1may be increased by removing the roof70, performing any necessary cleaning of the top of the top course40, adding additional courses40, and placing the same or a different roof70on top of the now top course40. Additionally, bands130may be added to courses40as appropriate to support additional stresses from the addition of new courses40. At a later date, if there is a desire for the storage structure1to no longer be placed at the site (wither to move the storage structure1to a new site, or demolish the structure), component pieces (roof70, and courses40) may be removed, top-to-bottom. The roof70may be disassembled into its component pieces (71,72,73), and courses40may be disassembled into their component pieces4. so the component pieces may be relocated at minimal cost. This modularity maximizes the value of a storage structure1by reducing demolition costs and providing additional markets for storage structures1.

In an alternative embodiment, the roof of the storage structure2100comprises a series of roof segments1900each of which is generally the shape of a truncated sector. The roof segments are preferably configured with a plurality of band attachment features. In a preferred embodiment, the band attachment features comprise a groove1902around the exterior1908of the roof segment1900and a groove1904near the interior1906of the roof segment1900. In certain embodiments, the series of roof segments1900may be configured with additional features for additional band(s). In a preferred embodiment, the roof segments1900are configured with tongue and groove features on the sides where they are configured to mate with adjacent roof segments. When placed side-to-side, the roof segments1900a-fform a disc with an open center2000. In a preferred embodiment, the bottom of the disc2000is concave. In a preferred embodiment, the bottom of the roof segments1900are configured with tongue and/or groove2202features where the roof2100is configured to rest on the top course40. The roof further comprises an outer cap2102. The outer cap2102is preferably the shape of a circular disc with an open center. The outer edge of the outer cap2102is configured to mate with the interior1906of the open center of the disc2000formed by the roof segments1900a-f. The roof further comprises an inner cap2104. The outer edge of the inner cap2104is configured to mate with the interior of the open center of the outer cap2102.

In a preferred embodiment, the roof2100is secured to the storage structure1. A plurality of roof brackets2306are preferably attached to the edge of the roof2100. A plurality of base brackets2310are preferably attached to or adjacent the base60. A plurality of bands2304are attached to the inner cap2104. The bands preferably pass over the brackets2306and are attached to the brackets2310adjacent the base60. In an alternative embodiment, a band2304passes from inner cap2104to a roof bracket2306and a separate band2302passes from the roof bracket2308to a base bracket2310. The bands2302and2304are then tightened to a desired tension.

In a preferred embodiment, the roof2100is assembled by preparing the sides of a roof segment1900a(e.g. by applying adhesive), placing another roof segment1900badjacent the first roof segment1900a, and repeating the process until a disc2000is created. One or more bands are then placed around the disc2000in the band attachment features (1902,1904) to hold the disc2000together. The top course40is then prepared as necessary, the disc2000is then lifted, preferably with a crane, and placed on the top course so tongue and groove features on the top course40mate with tongue and groove features in the bottom of the disc. The outer ring2102is then placed in the opening of the disc2000. The inner ring2104is then placed in the opening of the outer ring2102.

For purposes of this application, including disclosure and claims, tongue and groove features include any of a variety of radii greater than or equal to zero, including ball-and-socket joining features.