PATENT DOCUMENT

Abstract:
The invention relates to a method for producing cast structures, and a set of connectors for connecting a pair of opposed, spaced apart boards which are useful in said method. A kit of elements useful as support frames in the production of the cast structures is also provided.

Full Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to tools, methods and systems for constructing cast structures including walls, ceilings, columns and beams, and more specifically to tools, methods and systems for accurate construction of multilayer cast structures. 
       BACKGROUND OF THE INVENTION 
       [0002]    There are many methods and systems of constructing walls in the construction industry. Some methods involve the connection of pre-fabricated walls. Other methods involve time-consuming for laying of brick walls. 
         [0003]    Cast structures, e.g., walls, can be constructed by placing two spaced apart panels in parallel to each other, affixing said panels in their positions by means of suitable support means, pouring unhardened concrete into the space between said panels and allowing the concrete to cure. The panels may be either removed or remain in their place, and in the latter case, they may be designed to serve useful functions, such as thermal insulation. The resultant wall may be coated with plaster and/or stone. 
         [0004]    IL 124209 describes a building method using a plurality of framework elements for engaging and retaining vertical plates, and at least one sheet of rigid foamed insulation. 
         [0005]    US 2001/0027631 describes the construction of a concrete structure, using two opposed longitudinally-extending side panels, with a web member partially disposed within each of said panels, and connectors placed between the side panels for connecting the web members to each other. 
         [0006]    US 2004/0035073 discloses a three-dimensional construction module supported by mesh layers oriented transversally and longitudinally. 
         [0007]    One prior art method of constructing a standard cast wall, which may be plaster and/or stone coated and thermally insulated, requires many stages. This general methodology is prevalent in Israel and in the Middle East, in forming outer walls which have at least one outer layer of “Jerusalem limestone”. These many stages, performed by several different professional workmen, include: formwork preparation, metal reinforcement preparation, concrete casting, form dismantling, scafolds erection, waterproofing, applying thermal insulation, supporting the external coating stones by anchoring metal nets, stones cutting, stone drilling, stone laying, cementing the spaces between the stones, wall-face planarization, scaffolds dismantling, exterior wall cleaning, interior wall cleaning, thermal insulation preparation, (building an additional thin insulation brick wall while placing thermal insulation panels in between the two walls, perimeter construction, interior side plastering (with 3 plaster layers), perimeter dismantling, wall cleaning, and finally, costume-made window and door manufacturing and assembling. This is a stone-coated wall on an external side and plaster-coated on an internal side. Other kinds of walls may be coated on both sides homogeneously either by plaster or by stones, or might be partially or fully uncoated. This type of wall construction is physically very difficult and requires a major logistic effort prior to, during and after the construction process. Not only is this current methodology time-consuming, but is also very expensive. For instance, it requires the transfer of all the large construction equipment, such as plywood, heavy metal forms, large and heavy metal nets, to the construction site using big trucks and heavy duty cranes. 
         [0008]    In addition to wall construction, prior art method of construction of a standard cast ceiling, which may be plaster coated and possibly thermally insolated, requires many stages as well. These stages, also performed by several different professional workmen, include: formwork preparation, metal reinforcement, concrete casting, form dismantling, ceiling face planarization, scaffolds erection, interior side plastering with 3 layers plaster, scaffolds dismantling, and finally cleaning. 
         [0009]    Furthermore, prior art method of constructing columns and beams requires many stages as well, similar to those performed in building walls and ceilings. In other words, the cast structures, traditionally built in many stages, might be vertical (e.g., walls, and columns), horizontal (e.g., ceilings and beams), or diagonal (e.g., staircases and inclined elements). The multiple stage production of all these structures bears similar disadvantages. Moreover, current construction methods create a lot of dust, ground material and lead to both airborne and solid pollution. 
       SUMMARY OF THE INVENTION 
       [0010]    The invention relates to the production of cast structures which are uncoated, single-sided coated (e.g., a ceiling and an existing wall stone coating) and multiple-sided coated (e.g. walls, columns and beams), for example, a prevalent double-sided coated wall with an internal face and an external face that are coated with plaster and stones, respectively. The casting process is based on a unique method for setting up a support frame and affixing two spaced apart typically parallel boards which constitute the desired final coatings. The other contents of the wall (e.g., reinforcement rods, thermal insulation panel, service conduits and sealants) can be disposed between the two said boards and the concrete is finally poured into the space between the boards. Following the hardening of the concrete, a cast structure is formed, which is optionally reinforced, thermally insulated and sealed, with the desired coatings provided on its outer surfaces. 
         [0011]    Thus, board coatings, such as plaster coatings, which are traditionally applied on the hardened concrete upon completion of the casting stage, serve, according to the invention, in place of conventional formwork assembled at the pre-casting stage. 
         [0012]    The method, which involves the use of special connectors and construction elements for supporting, assembling and holding the boards, can also be applied for producing single-sided coated or uncoated cast structure, in which case at least one of the boards used is a temporary board (e.g., a plywood board). Following the concrete hardening, the temporary board or boards are removed to obtain an uncoated or one-sided coated cast structure. 
         [0013]    Accordingly, the term “board”, as used herein, is meant to include any permanently or temporarily used (planar or curved) board. The term “coating board”, as used herein, is meant to include any permanently used board for coating the cast structure, e.g., a plaster board, a cement board and a board made of stones. The term “temporary board”, as used herein, is meant to include any temporarily used board, e.g., a plywood board (preferably coated with formica), a plastic board and a metal sheet. 
         [0014]    As noted above, a first aspect of the invention relates to a device useful in the production of the cast structures, and more specifically, a device for supporting, assembling and affixing two essentially parallel, spaced apart boards in place relative to each other at the stage prior to concrete pouring. 
         [0015]    Accordingly, the invention provides a connector for a pair of opposed, spaced apart boards, said connector comprising two opposing ends and an elongate spacer extending therebetween, having at least one substantially horizontal locator member aligned perpendicular to the longitudinal axis of said elongate spacer, said horizontal locator being preferably in the form of a loop, and at least one substantially vertical locator member, extending from said spacer substantially perpendicularly to both the longitudinal axis of said spacer and to said horizontal locator member, said vertical locator being preferably in the form of a pair of cresses or a loop, wherein each of the two opposing ends of said connector is independently selected from the group consisting of:
       a. an end suitable for engaging coating boards other than stones board (for simplicity this end is referred to herein as a “plaster head”), said plaster head comprising a plate designed for back supporting said coating board, said plate having a rear side facing said elongate spacer and a front side from which coupling means are longitudinally extended, said means being preferably in the form of a conic head screw, wherein a groove and an expandable rim are preferably positioned between said front side and said coupling means, such that altering the position of said coupling means (e.g. screwdriving said screw) results in the expansion of said rim,   b. an end suitable for engaging a stones board (for simplicity this end is referred to herein as a “stone head”), said stone head being preferably wider than said elongate spacer and having an upper face and a lower face, with at least one pin extending vertically from both faces of said end, such that said pin is substantially parallel to the vertical locator (e.g., the pair of cresses), wherein said pin preferably has sharp ends capable of being inserted into corresponding holes in the engaged stones,   c. an end suitable for engaging a temporary board, (for simplicity this end is referred to herein as a “concrete head”), said concrete head preferably being thicker than said elongate spacer and having coupling means (e.g., a screw) extending longitudinally therefrom.       
 
         [0019]    The length of said elongate spacer of said connector, which is preferably made of plastic, is in the range from to 2000 mm (more preferably from 150 to 250 mm) corresponds to the thickness of the cast structure. 
         [0020]    The diameter of the horizontal loop and similarly, the distance between the pair of cresses extending vertically from the elongate spacer is from 5 to 100 mm, preferably from 10 to 30 mm. Accordingly, the horizontal loop and the pair of cresses can serve as locator for reinforcement rods, which are intended to be threaded therein. 
         [0021]    Regarding the plaster head, the useful function served by the expansion of the rim, positioned near the outer surface of the coating board, is that its diameter becomes substantially larger than the diameter of the coating board&#39;s hole, thus locking said coating board to said cast structure. 
         [0022]    Regarding the stone head, the diameter of the vertical pin provided at the stone head, which pin is typically made of steel, is from 2 to 15 mm (preferably 3 to 5 mm), and it extends by 5 to 50 mm (typically 10-15 mm) from the upper and lower faces of said stone head. The diameter of the plaster head and the concrete head is from 5 to 50 mm (preferably from 8 to 12 mm). 
         [0023]    As noted above, the connectors are used for affixing two essentially parallel, spaced apart boards in place relative to each other, defining a space between the boards, into which concrete is to be poured. The connectors, which are provided with a plaster head or a concrete head, are held to the respective boards (e.g., coating boards such as plaster or cement board, and temporary boards such as plywood boards) by means of a plate element (for simplicity this plate referred to herein as a “connector holder”). The plate, which is typically planar and preferably rectangular in shape, is attached to the outer side of the board (the side which is not facing the concrete receiving-space), thereby back supporting the board. The connector holder, e.g., the plate, has a hole similar to that of a keyhole shape, said hole being preferably centrally located in said plate, said hole comprising a first region with a first diameter and a second region with a second diameter, with the first diameter being smaller than the diameter of the head of the coupling member (e.g., the screw) provided in the plaster head or in the concrete head, said first region being preferably provided with reinforcement bend at its margin, and wherein the second diameter being larger than the diameter of the head of said coupling members designed for quick engaging and disengaging said coupling member of said plaster head and concrete head of said connectors. 
         [0024]    The dimensions of said connector holder, which is preferably in the form of a thin rectangular metal sheet, are 50-500 mm by 50-700 mm (preferably 100-300 mm by 100-300 mm), and thickness of about 0.1 to 10 mm (preferably 1 to 3 mm). Regarding the substantially centrally located hole of said plate, the diameter of its first region is from 3-25 mm (preferably 4-12 mm) and the diameter of its second region is from 6-60 mm (preferably 10-30 mm). A kit comprising the connector and the connector holder forms another aspect of the invention. 
         [0025]    Another aspect of the invention relates to another kind of device useful in the production of a cast structure, and more specifically, a device for producing a coated ceiling, which is coated by a coating board such as plaster board or stones board. Accordingly, the invention provides a connector ( 480 ,  490 ) for supporting said coating board, said connector comprising two opposing ends and an elongate spacer extending therebetween ( 481 ), wherein one end ( 482 ), designed to be anchored in the ceiling&#39;s concrete, is larger than said elongate spacer, and another end consisting of a plaster head or a stone head described above. 
         [0026]    Another aspect of the invention relates to another kind of device useful in stone coating an existing wall. Accordingly, the invention provides a connector ( 4100 ) comprising two opposing ends and an elongate spacer extending therebetween ( 4102 ), wherein one end ( 4101 ) consisting of said stone head and another end ( 4103 ) consisting of a “C-clamp” head ( 4106 ) in the form of a ring with a “V” shape opening in the perimeter of said ring ( 4105 ), designed to be clamped on the net anchored to said existing wall. 
         [0027]    Another aspect of the invention relates to another kind of device useful in the production of a cast structure, and more specifically, a device for supporting, assembling and affixing two adjacent stones boards typically none co-planar and often orthogonal to one another (for simplicity this connector is referred to herein as “stone corner connector”). Said stone corner connector (SCC) comprises a body and two pins, where said body, having upper and lower faces, comprises two ends and an elongate spacer extending therebetween, where each of the two connector&#39;s ends has a pin extending substantially perpendicularly from its faces and essentially parallel to one another, each pin optionally has sharp ends capable of being inserted into corresponding holes in the engaged stones, said elongate spacer has a cress extending substantially upward and an essentially horizontal loop extending laterally, and finally, said body has at least one hole for an engaging element used to engage it to a support frame. 
         [0028]    The length of said stone corner connector, typically made of polymeric material such as plastic, is between 20 and 1000 mm (typically 50 to 300 mm), the thickness of said connector, is between 1 and 100 mm (typically 5 to 30 mm), the diameter of each pin, which pin is typically made of steel, and the diameter of said cress is from 2 to 15 mm (preferably 3 to 5 mm), and they extend by 5 to 50 mm (typically 10 to 15 mm) from their faces, and the diameter of the horizontal loop is from 1 to 100 mm, preferably from 2 to 30 mm. Accordingly, the essentially horizontal loop and the essentially vertical cress can serve as locators for reinforcement rod and rim, respectively, which are intended to be threaded therein. 
         [0029]    A further aspect of the invention relates to a method for producing cast structures, comprising:
       a. assembling at least a pair of opposed, substantially parallel and spaced apart (planar or curved) boards, wherein each board is selected from the group consisting of coating boards and temporary boards, thus defining a filler-receiving-space between the inner faces of said pair of boards, wherein said assembling comprises affixing said pair of boards in place relative to one another by connecting them by means of connectors and holding said connectors by means of connector holders in the form of plates placed on the outer face of each said board, preferably forming an array consisting of rows and columns of said connectors in said filler-receiving-space, wherein each connector comprises an elongate spacer having at least one substantially horizontal locator member aligned perpendicular to the longitudinal axis of said elongate spacer, said horizontal locator being preferably in the form of a loop, such that said loop is normally horizontally aligned in the filler-receiving-space between said pair of boards, and at least one substantially vertical locator member, extending upwardly from said spacer substantially perpendicular to both the longitudinal axis of said spacer and to said horizontal locator member, said vertical locator being preferably in the form of a pair of cresses or a loop, such that said pair of cresses or loop is essentially parallel to said boards,   b. optionally threading horizontal and vertical reinforcement rods through said horizontally and vertically aligned locators of said array of connectors, respectively;   c. optionally disposing in said filler-receiving-space additional contents (e.g., insulation panel, service conduits and sealants) of said structure,   d. pouring filler into the concrete receiving space, and allowing the filler to cure,   e. Optionally removing said connector holders, and when temporary board is used, then removing said connector holders, said temporary board and said coupling members of the corresponding concrete head of each said connector.       
 
         [0035]    Preferably, the step of assembling the boards is preceded by affixing a vertical support frame, comprising vertical and, when necessary, diagonal profiles (e.g., right-angle profiles), mutually connected and optionally anchored to the floor. The method, set out above, may further comprise the step of disposing any additional contents of said cast structure (e.g., thermal insulation panels, service conduits and sealants) in the space between the pair of boards prior to filler addition. 
         [0036]    There is also provided, according to one embodiment of the present invention, a coated wall comprising:
       a. At least one pair of spaced apart, typically parallel, boards, wherein at least one board constitutes the desired final coating board made of e.g. plaster board, stones board or cement board,   b. A plurality of substantially horizontal connectors placed between said pair of boards and affixing said boards in place relative to one another, wherein each of said horizontal connectors comprises a pair of elements (locators) for positioning reinforcement rods (e.g. metal rods), said locators being oriented in planes which are perpendicular to one another, said connectors being preferably in the form described in detail above;   c. Optionally, reinforcement rods (e.g. metal rods) disposed between said boards forming a grid structure held in place by means of said connectors;   d. Optionally, sealant and/or other contents of said wall (e.g. insulation panels and service conduits) being placed between said boards,   e. Optionally, filler adapted to be poured into the gap between said boards and to set therein.       
 
         [0042]    In those cases where an opening of any shape needs to be provided in the cast structure, e.g. a rectangular window, then the invention further comprises assembling a frame of boards (e.g. marble stones), each being orthogonal to said coating boards and covering the thickness of the cast structure and a lintel, and casting a beam (preferably with reinforcement rods) on top of them, and when necessary, establishing an access for filler beneath the opening (e.g. the window) using at least one pipe serving as a funnel in order to fill the entire space beneath said opening by said filler. 
         [0043]    Another aspect of the invention relates to a method for producing suspended (planar or curved) cast structures, (e.g., a ceiling and/or a beam) comprising:
       a. affixing a substantially horizontal support frame (planar or curved), according to the shape of the desired cast structure,   b. placing on said support frame a (planar or curved) coating board,   c. engaging essentially vertically to said board a plurality of connectors and connector holders described above to said coating board,   d. affixing an additional typically vertical support frame, when side coating is required (e.g., in a coated beam), similar to that used for walls, and tangent to said structure, and engaging typically horizontally a plurality of connectors and connector holders when required,   e. optionally disposing one or more components selected from the group consisting of reinforcement rods and nets, insulated panel, bricks and service conduits of said suspended cast structure, and   f. Pouring filler, and after hardening, optionally removing said support frame, and said connector holders and screwdriving the engaging elements.       
 
         [0050]    Another aspect of the invention relates to a method of applying a stone coating on an existing wall, comprising:
       a. anchoring to said wall a net, preferably in the form of a grid of metal rods,   b. assembling a stones board using stone net connectors by means of clipping the net heads of said connectors onto said net, and maintaining filler-receiving-space between said wall and said stones board, and   c. Pouring filler in said filler-receiving-space.       
 
         [0054]    Another aspect of the invention relates to a kit of elements useful as support frames in the production of the cast structures set forth above, including erected structures (e.g., walls and columns) and suspended structures (e.g., ceilings and beams), said kit comprising:
       a. a right-angled profile element ( 530 ) in the form of a metal sheet which is bent along its length at an essentially right angle, wherein each of the two parts which are perpendicular to one another has a series of holes ( 531 ) along its length, wherein said holes are preferably evenly spaced;   b. a set of longitudinal hollow profiles, each in the form of rectangular parallelepiped in which two opposed lateral edges are open, (for simplicity referred to herein as “hollow profiles”), wherein each individual profile has a cross section which is dimensionally different from the cross section of other profiles in the set, such that said set is capable of being arranged in a first arrangement in which the individual profiles are entirely inserted one inside the other when said set needs to be relocated, shipped and stored, and in a second arrangement in which the profiles are partially inserted one inside the other, when said set is in use;   c. A profile gripping element  520  (for simplicity referred to herein as a “profile gripper”) for engaging the connector described above to said right-angle profile ( 530 ), said profile gripper comprising a first planar member and in connection therewith at an essentially right angle thereto a second member consisting of two parallel thin plates, said first member comprising an aperture which is preferably located at proximity to the intersection of said first member and one of said thin plates, wherein said parallel plates are spaced apart such that the gap therebetween corresponds to the thickness of a perforated part of said right-angled profile element ( 530 ) said aperature is a hole similar to that of a keyhole shape, comprising two kinds of holes, where one kind is circular and larger than the head of the connector&#39;s engaging element (e.g. the connector&#39;s screw), such hole is desiged for quick engaging and disengaging said coupling means of said plaster head and concrete head of said connector, and a second kind of holes, one above and one beneath the first kind of hole, such holes are elongate and smaller than said head of said coupling element (e.g. connector&#39;s screw head), such second kind of holes are designed for enabling gripping said right-angle profile either from its right side of from its left side, while having the weight of said profile gripper assisting and ensuring its locking effect to the engaging element;   d. a wedge insertable in the gap formed between a pair of said profiles, when said profiles are in said second arrangement, said wedge being positioned between the inner face of the lower base of the wider profile and the outer face of the lower base of the narrower profile, thereby attaching the upper bases of said profiles to one another; and   e. a flexible cable, preferably having two solid, (e.g. T-shaped), heads at its ends, such that each heads is capable of being inserted through a hole of said right-angle profiles and cancatinate each two adjacent profiles by essentially two typical spaced apart cable spacers, thus typically evenly spacing apart said profiles when used, and keeping them both cancatinated and stocked together when orderly relocated, shipped and stored.       
 
         [0060]    The right-angle profile, which is preferably made of a metal sheet, is 10-10000 mm by 10-100 mm (preferably 300-5000 mm by 30-60 mm); 
         [0061]    Said profile gripper is typically made of sheetmetal, and the dimensions of each of its members is 20-200 mm by 20-200 mm (preferably 30-100 mm by 30-100 mm); 
         [0062]    The set of said hollow profiles, typically rectangular metal, of dimensions 10-200 mm by 10-200 mm (preferably 20-100 mm by 20-100 m); 
         [0063]    The wedge is typically made of 8-100 mm by 8-100 mm by 8-100 mm steel; 
         [0064]    The cable, typically made of steel, is 20-200 mm long and 0.5-10 mm (usually 1-3 mm) thick. 
         [0065]    Another aspect of the invention relates to a method for using said support frame kit for establishing support systems for the construction of cast structures by:
       1. assembling the coating boards for erected structures (e.g., walls and columns) which is usually preceded by affixing a series of spaced apart (e.g. by 120 cm) vertical support profiles, comprising of vertical and, when necessary, diagonal right-angle profiles, mutually connected and preferably anchored to the floor, said cast structure is usually fastened to said vertical support profiles by means of the profile grippers; and,   2. assembling the coating boards for suspended structures (e.g., ceilings and beams), which is usually preceded by establishing essentially a horizontal support frame including:
           a. disposing hollow profiles (serving as support frame beams), typically parallel to one another and spaced apart (e.g., by 1 meter), on top of standard construction jacks, e.g. narrower profiles partially inserted into wider ones, where each set of overlapping parts are optionally commonly supported by a jack, and where a wedge is inserted between them at their bottom faces in order to insure that their upper parts are mutually attached to one another, or alternatively, supporting said narrower hollow profile by a jack near said overlapping regions and having the wider profile suspended on the narrower one,   b. disposing right-angle profiles on top of said hollow profiles, spaced apart (e.g., by 10 cm) by at least two typically identical cable spacers connecting each two adjacent profiles, and having said profiles oriented, for example at a v-shape (for maximizing the support area of the coating board disposed on top of them), said right-angle profile partially overlaps longitudinally an adjacent one extended longitudinally, where each pair of overlapping parts are supported by a hollow profile.   
               
 
         [0070]    Another aspect of the invention relates to a method of using said support frame kit for supporting wall-to-ceiling connection, which includes the following steps used, for instance, for stone-plaster wall when connected to plaster coated ceiling:
       a. connecting horizontally a right-angle profile to said vertical profiles such that one part of this profile is essentially parallel to said stones board while its perpendicular counterpart is perpendicular to said stones board and pointing away from it (for simplicity this horizontal profile is referred to as a “profile rail”), said profile rail is positioned slightly above the top aspect of the ceiling while leaving an opening space between said profile rail and said ceiling&#39;s coating plaster board, such opening is left for enabling reinforcement rods and concrete to pass from the ceiling onto the wall, while previously, said vertical profiles are covered by solid sleeves (pipes) at the height of the ceiling, along its thickness, to protect said vertical profiles from being locked by the ceiling&#39;s fresh concrete,   b. adding an additional row of stones on top of the wall&#39;s stones board (for simplicity this row of stones is referred to as a “stone rail”), such stone rail is destined to both prevent the fresh ceiling&#39;s concrete from spilling over the wall, and ultimately coat the side of the ceiling,   c. Connecting said profile rail to said stone rail using stone-plaster connectors together with profile grippers for gripping said profile rail to withstand the weight of the ceiling&#39;s fresh concrete.       
 
         [0074]    Another aspect of the invention relates to a method of using the support frame kit for supporting wall-to-wall connections, which includes the support of each of the two sides of the wall-to-wall right-angle connection, for instance, by said right-angle profile, and fastening them either by metal wires, or by plaster-plaster connector, for instance, or in some cases, e.g. when stone-plaster walls are mutually connected, then stone corner connector (SCC) can be used for the external stone corner, while the internal corner can be supported by the regular connectors, including their corresponding connector holders, provided that these connectors are located close enough to the edge of the internal corner and a narrow connector holder  510   a  is used. 
         [0075]    In summary, the present invention deals with an ergonomic strategy and a system of connectors and a kit of elements which enable the performance of all the construction stages of cast structures in one consolidated stage by one single specialist. It is designed to be performed substantially quicker than the prevalent construction methods while saving a lot of human motion and energy. The entire assembling process, according to the invention, can be performed from one side of the cast structure, e.g. the inner side of a building, and it creates almost no residues of construction material. It enables the precise fitting of the openings in a cast structure to the previously manufactured lintels of windows, doors and trellises and not visa versa, thus avoiding the need for custom made production of each window, door and trellises for each opening. The final result of this method is a constructed (planar or curved) unit having the same basic components of the one obtained by the prevalent construction methods, having the advantage of most said coating boards being dis-assembelable and re-assemblable for possible future changes. The construction process here is substantially less time consuming and with less pollution and less manpower—particularly professional expensive one. Therefore, it involves considerably lower costs compare to that of the prevalent construction methods. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0076]    In the drawings: 
           [0077]      FIGS. 1A-1B  show perspective front and rear views of a double-sided stone-plaster wall, in accordance with some embodiments of the present invention; 
           [0078]      FIGS. 2A-2B  show perspective front and rear views of various categories of walls and ceilings, in accordance with some embodiments of the present invention; 
           [0079]      FIGS. 3A-3B  show perspective front and rear views of a multi-sided columns and beams, in accordance with some embodiments of the present invention; 
           [0080]      FIG. 4  shows perspective views of various connectors for constructing cast structures, in accordance with some embodiments of the present invention; 
           [0081]      FIG. 5  shows construction elements for constructing cast structures, in accordance with some embodiments of the present invention; 
           [0082]      FIG. 6  is a simplified flow chart of a method for constructing a double-sided stone-plaster coated wall; in accordance with some embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0083]    The current invention concerns a construction method of cast structures such as walls, ceilings, columns and beams, including devices therefore. More specifically, the invention employs ergonomic strategy for fast and efficient construction of cast structures, using appropriate connectors and tools. These structures are coated with a plaster board and/or stones, or partially or fully uncoated. They optionally include reinforcement grids of horizontal and vertical metal rods, thermal insulation panels, sealants, service conduits and apertures for windows and/or doors. They are typically supported by support frames comprise of vertical, diagonal and, if required, horizontal profiles. 
         [0084]    The construction method, according to the invention, is aimed at producing various categories of walls, ceilings, columns and beams as described below:
       a. stone-plaster wall—a stone coated wall typically on the outside and plaster board typically on the inside,   b. plaster-plaster wall—a plaster coated wall on both sides,   c. stone-stone wall—a stone-coated wall on both sides,   d. stone-concrete wall—a stone-coated wall on one side whereas the other side is uncoated,   e. plaster-concrete wall—a plaster coated wall on one side whereas the other side is uncoated,   f. concrete-concrete wall—fully uncoated wall,   g. plaster coated ceiling,   h. stone coated ceiling,   i. Partially or fully uncoated ceiling.       
 
         [0094]    Reference is now made to  FIGS. 1A-1B , which show perspective front and rear views of the double-sided stone-plaster wall  100 , in accordance with some embodiments of the present invention. Wall  100  comprises an internal surface  130  and an external surface  140 . Usually, the external surface may be exposed to the environment, and the internal surface is, in some cases, within a building. 
         [0095]    External surface  140  is coated with stones  101  and the internal surface comprises, for example, a plaster board  102 . The wall may be vertically supported by one or more support frames  103 . Disposed between surfaces  140  and  130 , there may optionally be a thermal insulation panel  106 , which may be attached to plaster board  102 . In addition, stone-plaster connectors (SPC)  107 , together with connector holders  108 , provide connection and support for the plaster board surface and the stone surface. Additionally, profile grippers  109  grip on vertical profiles  150  of the support frames to attach them to the plaster surface. The stone-plaster connectors, connector holders, and grippers  109  are described in more detail herein below in  FIGS. 4 and 5 . Each row of stone-plaster connectors creates, with their pairs of vertical cresses  104 , a pair of “virtual horizontal canals”  118  through which horizontal metal rods  110  may be disposed. Additionally, each vertical column of stone-plaster connectors creates, by vertical alignment of their loops  105 , a pair of “virtual vertical tunnels”  119 , for the positioning of the vertical rods  111 . In other words, the cresses and the loops of the stone-plaster connectors serve as locators for the metal grids  160 . 
         [0096]    Each hole  112  in plaster board  102  is typically 10 mm in diameter, which is slightly larger than the diameter of the plaster head  412 , which is typically 9 mm (see  FIG. 4 ). Each hole  113  in a thermal insulation panel  106  coincides with its corresponding hole  112  in the plaster board. However, the diameter of holes  113  is much larger, e.g. 40 mm, than that of holes  112 . This is designed as such in order to enable concrete  170 , or other hardener, upon pouring thereof between the two surfaces  140  and  130 , to penetrate holes  113  so that they create short horizontal columns to back-support the plaster board after the concrete hardens. The horizontal distances between holes  112  are usually identical, and the vertical distances between these holes are usually identical. Pins  115  of the stone-plaster connectors may be disposed, for example between a floor and  101 , or between two vertically adjacent stones. Service conduits  116 , include, but are not limited to conduits for water, sewage, drains, electrical and communication wires and gas. These conduits are disposed between the stone and plaster surfaces. The conduits may optionally be inserted in the thermal insulation panel  106  so that they are more easily removed, added or relocated in the future after the wall has been completed. Spaces  114  may exist between any adjacent stones and may be of around 1 cm. Metal wires  120  can optionally be inserted into additional stone holes and wrapped around horizontal rods  110  to enhance the stone anchoring effect to the concrete. Sealant  121  is typically spreaded or sprayed on the back of stones  101  and in spaces  114  to prevent any penetration of humidity into the wall. 
         [0097]    Reference is now made to  FIGS. 2A-2B , which show perspective front and rear views of walls  200  and ceilings  280  and  290 , in accordance with some embodiments of the present invention. 
         [0098]    Double-sided stone-stone wall  210  includes an external stone surface  211  and an internal stone surface  212 . This wall is similar to the stone-plaster wall, described in  FIG. 1 , except that the internal plaster surface  102  ( FIG. 1 ) is replaced here by the stone surface  212 , and that the stone-plaster connectors  107  are replaced here by the stone-stone connectors  213 , described in further detail herein below in  FIG. 4 , connector  430 . 
         [0099]    Double-sided stone-concrete wall  220  comprises an external stone surface  221  and internal removable plywood  222 . This wall is also similar to the stone-plaster wall, described in  FIG. 1 , except that the internal plaster surface  102  ( FIG. 1 ) is replaced here by removable plywood  222 , and therefore the stone-plaster connectors  107  ( FIG. 1 ) are replaced here by stone-concrete connectors  223 , described in further detail herein below in  FIG. 4 , connector  460 . 
         [0100]    Double-sided stone-plaster walls  230  are similar to stone-plaster wall  100  ( FIG. 1 ) and therefore connectors  233  of these walls are similar to stone-plaster connectors  107 , described in further detail herein below in  FIG. 4 , connector  410 . 
         [0101]    Walls  230  contain window/door aperture  234 , in accordance with some embodiments of the present invention. It has a window frame lintel  239 . The “lips” of the window aperture include right-angle stones  235 , located along the sides of the window frame, and long flat stones  236  and  237  below and above it, respectively. At the internal side of wall  230  at least one concrete feeding hole and funnel  239   b  is used in the plaster board beneath the window frame through which the concrete is poured below the window. In wide apertures of windows or doors, the upper side of lintel  239  and/or stone  237  might bend, or even break, due to the weight of the fresh concrete. In order to avoid such phenomena, pouring the concrete above the window aperture is done in two stages as follows. First, a thin concrete layer (e.g. 10-15 cm) is poured above the aperture and on metal reinforcement rods  258   a  to create beam  258 , which is named here an “eye braw”. This is done after the part of each right-angle stone  235 , coming into the window aperture, is supported firmly from beneath it. And second, after the “eye brow” hardens, the rest of the concrete above the window is poured. It should be noted that, prior to pouring the concrete of the “eye brawn”, thin sheet metal spacers  239   a  are placed between lintel  239  and stones  235 ,  236  and  237 . This makes lintel  239  removable after the concrete hardens by, first, removing spacers  239   a , and then removing lintel  239 . However, if spacers  235 ,  236  and  237  would not be used, then lintel  239  might be locked and not removable after the concrete hardens. 
         [0102]    Double-sided plaster-plaster wall  240  comprises an external plaster surface  241  and internal plaster surface  242 . Again, this wall is similar to the stone-plaster wall, described in  FIG. 1 , except that the external stone surface  101  ( FIG. 1 ) is replaced here by the plaster board surface  241 , and hence stone-plaster connectors  107  are replaced here by plaster-plaster connectors  243 , described in further detail herein below in  FIG. 4 , connector  420 . 
         [0103]    Double-sided plaster-concrete wall  250  includes external removable plywood  251  and an internal plaster board surface  252 . This wall is similar to the stone-plaster wall, described in  FIG. 1 , except that the external stone surface  101  ( FIG. 1 ) is replaced here by the removable plywood board  251 , and that the stone-plaster connectors  107  are replace here by plaster-concrete connectors  253 , described in further detail herein below in  FIG. 4 , connector  450 . 
         [0104]    Double-sided concrete-concrete wall  260  includes external removable plywood  261  and also internal removable plywood  262 . This wall is, again, similar to the stone-plaster wall, described in  FIG. 1 , except that both external stone surface  101  and internal plaster surface  102  are replaced here by removable plywood boards  261  and  262 , respectively, and therefore stone-plaster connectors  107  are also replace here by concrete-concrete connectors  263 , described in further detail herein below in  FIG. 4  connector  440 . 
         [0105]    The connections between walls  200  include two types of corners: internal corners  215 ,  224 ,  245  and  254 , and external corners  214 ,  225 ,  224  and  255 . Frequently, connections between walls are supported here by a profile at the internal corner, and another profile at the external corner, which are fastened to one another by a connector and/or a wire (see, for instance,  227  and  257 , respectively). In some cases, internal corners can be supported by the regular connectors, appearing at the connected walls, provided that the connectors are located close enough to the edge of the internal corner (e.g. corner  215 ). In other cases, external stone corner can be supported by external stone corner connector  228 , described in further detail herein below in  FIG. 4 , connector  4120 . 
         [0106]    Wall  270  is an existing wall, which is supposed to be coated by coating stones  272 . Stone anchoring net  271  is anchored to wall  270  by bolts  274  and discs  275 . Wedge  276  is used to help level the net in the desired plain, typically but not necessarily, vertical. Stones  272  are anchored to net  271  using stone-net connectors  273 , similar to that described in further detail herein below in  FIG. 4 , connector  4100 . 
         [0107]    Reference is now made to ceilings  280  and  290  in  FIGS. 2A-2B , in accordance with some embodiments of the present invention. Ceilings  280  and  290  sit on a pergola assembly comprising of jacks  231 , profile beams  232   a  and  232   b  and profiles  284 , including wedges  232   c  and cable spacers  232   e . Jacks  231  are standard jacks used in the field of construction, where their heights are adjustable. Profile beams  232   a  and  232   b  are typically hollowed rectangular profiles. They are similar in dimensions while one can be inserted inside the other. For instance, profile beams  232   a  and  232   b  can be of 60×30 and 50×25 mm hollowed rectangular profiles, respectively, with wall thickness of around 1.5 mm. Thus, profile beam  232   b  can be entered into profile beam  232   a  while wedge  232   c  is inserted in between them to compensate for the few millimeter difference in their width to assure that their top aspects reach similar height. Note that beneath the overlapping parts of each pair of beams (and wedge  232   c ) jack  231  is placed for reaching maximal strength at the support area. Wedge  232   c  has hole  232   d  for anchoring cables to laterally support beams  232   a  and  232   b , typically anchored to the floor or to a neighboring beam. Safety pin can also be used to connect between each pair of neighboring profile beams. 
         [0108]    Typically, profiles  284  are placed orthogonally on top of profile beams  232   a  and  232   b . Profiles  284  are typically equally spaced, e.g. 15 cm apart from one another, and each one of them is oriented at a “v-shape”, in order to have a large interface and support for the plaster board placed on top of them. Thin cable spacers  232   e , which have solid stoppers  232   f  at their ends, are used for two purposes as follows:
       a. fast and easy laying out and folding them on top of the profile beams,   b. Fastening them at their “v-shape” position while maintaining them equally spaced.       
 
         [0111]    Note that the overlapping part of each neighboring profiles  284  must be supported by a profile beam in order to avoid possible collapse. 
         [0112]    The selection of such profiles is done because of a number of reasons as described bellow:
       a. Both kinds of profiles are easily overlappable and adjustable to the necessary length and width of the constructed ceiling.   b. They are easily laid out and folded.   c. At their folded and packed positions they are extremely compact and easily moved and/or shipped either inside the construction site or between construction sites.   d. They occupy minimal storage space, in comparison with most of the heavy duty forms and woods traditionally used.       
 
         [0117]    Plaster coated ceiling  280  is viewed here as a sort of horizontal wall, where its bottom face is viewed here as the internal aspect of this “wall”. In this view, its internal plaster board surface  281  serves as, sort of, lining, and therefore it is similar to internal plaster board surface  102  of stone-plaster wall, described in  FIG. 1 , except that stone-plaster connectors  107  are replaced here by plaster-ceiling connectors  283 , described in further detail herein below in  FIG. 4 , connector  480 . Just like stone-plaster wall  100  ( FIG. 1 ), supported by profiles  103 , optionally thermally insolated by thermal insulation board  106 , and its connectors are held by connector holders, also here, ceiling  280  is supported by profiles  284 , optionally thermally insolated by thermal insulation board  282 , and plaster-ceiling connectors  283  are held by either connector holders or profile gripper at the ceiling&#39;s bottom (not seen), described herein below in  FIG. 2A . And also the ceiling support arrangement of jacks  231 , profile beams  232   a  and  232   b  and profiles  284  is depicted in detail in  FIG. 2A  as well. Note that edges  281   a  of the two adjacent plaster boards are supported by the same profile, and they are also sealed by tape  281   b  in order to prevent fresh concrete leakage. Bricks  285  are often placed on ceilings, where spaces  286  in between them form the beams and the ribs of the ceiling. Just like in stone-plaster wall  100  ( FIG. 1 ), service conduits  287  include, but are not limited to, conduits for electric and/or communication wires. These conduits are disposed above plaster boards  281  and possibly inside groove  282   a  of thermal insulation board  282 , so that they are more easily removed, added or relocated in the future after the ceiling has been completed. 
         [0118]    Stone coated ceiling  290  is also viewed here as a, sort of, horizontal wall, where its bottom is the internal aspect (or lining) of this “wall”. In this light, again, internal plaster surface  102  in  FIG. 1  is replaced here by stone surface  291 , except that stone-plaster connectors  107  are replaced here by stone-ceiling connectors  293 , described in further detail herein below in  FIG. 4 , connector  490 . Note that the stone-net connector  292  can also be used, particularly when an anchoring net is placed on top of stone surface  291 . 
         [0119]    Walls  200  contain wall-ceiling connection preparation  264  at the tops of them, in accordance with some embodiments of the present invention. Beyond the tops of walls  200 , at their external surfaces, an additional row of stones  269 , or plaster boards  243  (or plywood), called external ceiling rail, is assembled. This external rail is connected to (internal) profile rail  265  by any appropriate connectors (according to the kind of the connected wall) and profile grippers  266 , which grip on profile rail  265 . Each vertical profile of the support frame is protected from the ceiling&#39;s concrete by solid sleeve  267 . After the ceiling&#39;s concrete hardens, each sleeve  267  forms a vertical hole in the ceiling. This hole serves as a passage for lifting support frames (and possibly additional items) for the construction of the next floor, without having to put apart the support frame. Note that there is opening  268  beneath each profile rail  265  since there is no plaster board, plywood or stones against external ceiling rail  269 . The role of this opening is to enable the placement of the ceiling&#39;s concrete and metal reinforcement rods, coming from the internal side of the wall, to be on top of the connected walls. 
         [0120]    Reference is now made to  FIGS. 3A-3B , which show perspective front and rear views of a multi-sided, columns and beams, in accordance with some embodiments of the present invention; 
         [0121]    Reference is now made to plaster coated column  340  and stone coated column  330  in  FIGS. 3A-3B , in accordance with some embodiments of the present invention. Columns are viewed here as narrow walls. Therefore, unlike walls  200  described in  FIGS. 2A-2B , which are supported at one side only, columns need to be supported at more than one side. Thus, support frames may appear at more than one side and/or their corners as well. 
         [0122]      FIGS. 3A-3B  show perspective front and rear views of plaster coated column  340 . It is supported vertically by support frame  347 , and when necessary, additional support frames  354  might be added, together with profile grippers  355 , described in further detail herein below in  FIG. 5 , element  520 . Here, plaster-plaster connectors (PPC)  342 , connector holders  343  and profile grippers  355  are used to connect plaster boards  341  in the same manner as they are used to connect the plaster surfaces of plaster-plaster wall  240  in  FIGS. 2A-2B . Reference numeral  345  represents the metal reinforcement rods, which are assembled vertically, and reference numeral  335  represents the metal reinforcement rims, which are assembled horizontally. Note that plaster-plaster connectors  342  might also connect pairs of vertical profiles, which can also be located at corners, diagonal to one another. 
         [0123]      FIGS. 3A-3B  also show perspective front and rear views of stone coated column  330 . This column is also supported vertically by support frame  337  and, when necessary, additional support frames  365  might be added, together with profile grippers  317 . Here, every two adjacent stones  331  are mutually connected by stone corner connector  332 , similar to connector  4120  described in  FIG. 4 . Here, stone-stone connectors (SSC)  333  can be added and used in the same manner as they are used to connect the stone surfaces of stone-stone wall  210  in  FIGS. 2A-2B . Also here, reference numeral  334  represents the metal reinforcement rods, assembled vertically, and reference numeral  335  represents the metal reinforcement rims, assembled horizontally. Finally, note that the support frames can be fastened to the stone connectors (either  332  or  333 ) by screw  332   a , and/or wire  332   b  and/or profile grippers  317 . 
         [0124]    Reference is now made to plaster coated beam  350  and stone coated beam  360  in  FIGS. 3A-3B , in accordance with some embodiments of the present invention. Beams are viewed and treated here as hybrid structures of both ceilings and walls. Therefore, on the one hand, they are supported by jacks and profiles from the bottom, as ceilings  280  and  290  in  FIGS. 2A-2B . And, on the other hand, they are also supported by support frames  347  and  365 , similar to walls  200  in  FIGS. 2A-2B . More specifically, in plaster coated beam  350 , the lateral plaster surfaces  351  are connected to one another by plaster-plaster connectors  352 , and connector holders  353 , similar to those of plaster-plaster wall  240  in  FIGS. 2A-2B , And, in its bottom plaster board, plaster-ceiling connectors (not seen) are used, similar to those used in plaster coated ceiling  280  in  FIGS. 2A-2B . Similarly, in stone coated beam  360 , lateral stone surfaces  361  are connected to one another by stone-stone connectors  361 , similar to stone-stone wall  210  in  FIGS. 2A-2B . And, in its bottom stones, stone-ceiling connectors (not seen) are used, similar to those used in stone coated ceiling  290  in  FIGS. 2A-2B . Finally, when necessary, the top aspect of beams  350  and  360  are coated right after the concrete is poured. Note that beam  350  can be converted to partially or fully uncoated beam if its plaster boards are removed. 
         [0125]    Turning now to  FIG. 4 , there can be seen various construction connectors for constructing cast structures such as walls, ceilings, columns and beams, in accordance with some embodiments of the present invention. 
         [0126]      FIG. 4  shows a perspective view of a stone-plaster connector (SPC)  410 , similar or identical to stone-plaster connector  107  ( FIG. 1 ), typically made of a polymeric material. Such material, typically made of a special cross linked high density polyethylene, is used to withstand high mechanical loads for many years at extreme environmental conditions such as plus/minus 110 degrees centigrade. Connector  410  is constructed and configured to which fastens stone  101  and plaster board  102  to the concrete  170  inside wall  100  ( FIG. 1 ). The connector includes three parts: a stone head  411 , a plaster head  412 , and a body  413 . The stone head  411  includes a relatively thick part  414 , of around 1 cm in thickness, for bearing the weight of stone(s)  101  and for serving as a spacer between stones, and a sharp pin  415  which is inserted into the stone holes for fastening the stones to the concrete of the wall. Each sharp end of the pin is designed primarily to serve as a guide to ease the insertion of the pin into the stone hole—especially into an aperture  180  (not shown) located at a lower surface of stone  101  ( FIG. 1 ), which are invisible during the assembling process. The plaster head  412  includes a screw  416 , having a conic head  402  for fastening the plaster board to the wall, and an end plate  417  for supporting the plaster board from a rear side. The diameter of both the plaster head  412  and that of the screw head is slightly smaller, e.g. 9 mm, than the diameter of the hole in the plaster board, e.g. 10 mm. When the screw is driven into the connector  410 , its conic head expands the connector&#39;s lips  403  to around 13 mm, which become larger than the diameter of the plaster board aperture hole (10 mm), and this tightens the plaster board to the concrete cast in the wall. The connector&#39;s body  413  includes two pairs of vertical cresses  418 , or more or less, if required, which are configured in parallel to pin  415 , and a couple of horizontal loops  419  (or more or less, as required), which are orthogonal to pin  415 . The pairs of cresses are constructed and configured to aid the placing in position of horizontal metal reinforcement rods  110  there between ( FIG. 1 ) in such a way such that a row of parallel connectors create a pair of “virtual horizontal canals”  118  between cresses  418 , as is seen in  FIG. 1 , for the placement of the horizontal metal rods. 
         [0127]    Similarly, two loops  419  are designed for positioning the vertical rods  111  so as to form a vertical column of loops thereby creating a couple of “virtual vertical tunnels”  119 , disposed to receive the vertical metal rods. In other words, the cresses and loops avoid the need to tie the rods for forming metal grids  160   
         [0128]      FIG. 4  also shows a perspective view of plaster-plaster connector (PPC)  420 , similar or identical to plaster-plaster connector  243  ( FIGS. 2A-2B ). It connects two plaster boards, such as plaster boards  241  and  242 , to the concrete of plaster-plaster wall  240 , seen in  FIGS. 2A-2B . Plaster-plaster connector  420  is similar to stone-plaster connector  410 , except that the stone head is replaced here by the plaster head. 
         [0129]      FIG. 4  shows also a perspective view of stone-stone connector (SSC)  430 , similar or identical to stone-stone connector  213  (seen in  FIG. 2A ). It connects two stone surfaces, such as stone surfaces  211  and  212 , from both sides of the concrete of stone-stone wall  210  (seen in  FIGS. 2A-2B ). Stone-stone connector  430  is similar to stone-plaster connector  410  (in  FIG. 4 ), except that its plaster head  412  is replaced here by a stone head, with screw  436  added to it for fastening the connector to a support frame using profile gripper  520  (seen in  FIG. 5 ). 
         [0130]      FIG. 4  shows a perspective view of concrete-concrete connector  440 , similar or identical to concrete-concrete connector  263  (seen in  FIGS. 2A-2B ). It connects two thin removable boards, such as removable boards  261  and  262  (typically made of 4 mm thickness plywood, a plastic board or thin sheet metal) to the concrete of wall  260  (seen in  FIGS. 2A-2B ) in a similar way as stone-plaster connector  107  connects stones  101  to plaster board  102 , where connector holder  108  is used (see  FIG. 1 ). However here, the thin removable boards are destined to be removed soon after the concrete hardens, and hence the concrete remains exposed. The diameter of concrete head  443  (typically 13 mm) is greater than the diameter of the holes (typically 10 mm) of the removable board. It is designed as such in order to back support the removable board. 
         [0131]      FIG. 4  also shows a perspective view of plaster-concrete connector  450 , similar or identical to plaster-concrete connector  253  (seen in  FIGS. 2A-2B ). It connects a plaster board to a thin removable board, for instance plaster board  252  to removable board  251  in plaster-concrete wall  250  (seen in  FIGS. 2A-2B ). Plaster-concrete connector  450  is similar to stone-plaster connector  410 , except that the stone head of connector  410  is replaced here by the concrete head. 
         [0132]      FIG. 4  shows also a perspective view of stone-concrete connector  460 , similar or identical to stone-concrete connector  223  (seen in  FIGS. 2A-2B ). It connects a removable board to a stone surface such as removable board  222  to stone surface  221  of stone-concrete wall  220  (seen in  FIGS. 2A-2B ). Also here, Stone concrete-connector  460  is similar to stone-plaster connector  410 , except that the plaster head is replaced here by the concrete head. 
         [0133]      FIG. 4  shows a perspective view of an adaptable connector  470 . The components of connector  470  are concatenated by screws  471 ,  473  and  475 . Adaptable connector  470  is often used for various circumstances where the distance varies between the stone plane and the plaster board plane (or the concrete plane). While the two heads here of the connector resemble the stone head and the plaster head of stone-plaster connector  410 , depicted in  FIG. 4 , it is meant to depict here all the permutations of all the 3 various heads (e.g. stone, plaster and concrete), described in  FIG. 4 . 
         [0134]      FIG. 4  shows a perspective view of plaster-ceiling connector  480 , similar or identical to plaster-ceiling connector  283  (seen in  FIGS. 2A-2B ). It connects plaster board  282  ( FIGS. 2A-2B ) to ceiling  280  in the same manner as stone-plaster connector  107  connects plaster board  102  to the concrete of wall  100  ( FIG. 1 ). 
         [0135]      FIG. 4  shows a perspective view of stone-ceiling connector  490 , similar or identical to stone-ceiling connector  293  (seen in  FIGS. 2A-2B ). It connects stones  291  ( FIGS. 2A-2B ) to ceiling  290  in the same manner as stone-plaster connector  107  connects stones  101  to the concrete of wall  100  ( FIG. 1 ). 
         [0136]      FIG. 4  shows a perspective view of stone-net connector  4100 , similar or identical to stone-net connector  273  (seen in  FIGS. 2A-2B ). It is used for stone coating an existing wall (or ceiling) such as wall  270  described in  FIG. 2B . Stone-net connector  273 , typically made of a polymeric material such as plastic, is constructed and configured to which fastens stones  272  to stone anchoring net  271  depicted in  FIG. 2B . Stone-net connector  4100  includes 3 parts: stone head  4101 , net head  4103 , and body  4102 . Stone head  491  is similar or identical to stone head  411  of stone-plaster connector (SPC)  410 , depicted in  FIG. 4 . Net head  4103  is a ring with a “V” shape opening  4105  to enable clipping the connector to the net&#39;s wire, which has similar or identical diameter to that of the net&#39;s head hole  4106  of the connector. 
         [0137]      FIG. 4  also shows a perspective view of wedge  4110 , similar or identical to wedge  276  depicted in  FIG. 2B . Wedge  4110 , typically made of a polymeric material (such as plastic), is used to guarantee that the stone anchoring net  271  is constantly vertical or uniformly inclined in the desired orientation. The circular grooves  4111  have similar or identical radius as that of the wires of stone anchoring net  271 , depicted in  FIG. 2B . Wedge  4110  is essentially an adaptable spacer between the anchoring net and the existing wall. 
         [0138]      FIG. 4  shows a perspective view of a stone corner connector (SCC)  4120 , similar or identical to stone-corner connector  228 , described in  FIGS. 2A-2B . Stone-corner connector, typically made of a polymeric material such as plastic, connects two adjacent stone surfaces  211  and  221  of wall  220 , usually at a corner, as described in  FIGS. 2A-2B . It is also often used at corners of stone coated columns, such as stone corner connector  332 , of stone coated column  330 , described in  FIGS. 3A-3B . The connector includes a thick body  4123  of around 1 cm thickness, which also serves as a spacer between stones. It typically comprises of two (typically metal) sharp pins  4125 , which are inserted into the stone&#39;s apertures (not shown) for fastening the stones to each other. The sharpness of each pin is usually designed to serve as a guide to ease the insertion of the vertical pin into the aperture (not shown), especially those located at a lower surface of the assembled stone (which are invisible during the assembling process). Screw  4126  is designed to fasten the stones surface to a support frame using a profile gripper. The other holes, such as  4124  and  4127  are designed to provide additional possibilities for fastening the connector to supporting profiles. Cress  4128  is designed to guide and hold a horizontal metal rim, such as rim  335  in column  330 , depicted in  FIGS. 3A-3B . Loop  4129  is designed to guide and hold a vertical metal rod, such as rod s  334 , seen in  FIGS. 3A-3B . In other words, the cress and loop avoid the need of tying the metal reinforcement rods and rims to each other, as in prior art systems. 
         [0139]    Reference is now made to  FIG. 5 , which shows various construction elements  510 ,  510   a ,  520 ,  530  and  540  for constructing cast structures such as: walls, ceilings, columns and beams, in accordance with some embodiments of the present invention. 
         [0140]      FIG. 5  shows a front view of connector holder  510 . It is typically a rectangular plate, often made of metal. Typical dimensions may be, for example, 20 by 15 cm. In one embodiment, it is made of a sheet metal, and comprises reinforcement support bends or elements  511 . This design enables the connector holder to be as light as possible, yet provides significant mechanical strength. 
         [0141]    The connector holder comprises of hole  512  of roughly keyhole shape. The hole includes a narrow part of around 5 mm, to hold the neck of the connector&#39;s screw  416 , described in further detail in  FIG. 4 , and a wide part, of around 12 mm for quick and easy insertion and receiving of the screw head. Usually, the hole is placed essentially in the center of the plate. However, in some circumstances it is located close to the edge of the plate, e.g. in cases where it needs to be positioned at the edge of the wall. Connector holder  510   a  serves as an example for edge connector holder. An example of its usage can be seen in the bottom row of connector holders of wall  100  (seen in  FIG. 1B ). 
         [0142]      FIG. 5  also shows a perspective view of a profile gripper  520 . This plate, typically made of a sheet metal, includes two mutually perpendicular parts, resembling a book end. Part  524  is flat and has a hole  522  of a keyhole shape, similar to or identical to hole  512 , except that hole  522  has two, as apposed to one, narrow parts. The narrow parts of the hole are designed to hold the screw of a connector at its neck, and the wide part of the hole serves as a passage for a quick and easy insertion of the head of the screw. Part  521  includes bending of about 180 degrees and it is designed to grip on the profile as depicted in assembly  540 . The two narrow parts allow gripping a profile at its either side. 
         [0143]      FIG. 5  shows also a perspective view of profile  530 , typically made of sheet metal, which is long and bent longitudinally at a right angle with equally spaced holes  531  along its length. It is often used for forming support frames to vertically support cast structures as seen in  FIGS. 1-3 . It is also used for creating a profile ceiling rail  265  as described in  FIGS. 2A-2B , as well as support for ceiling (e.g., profiles  284  in  FIG. 2A ). 
         [0144]    Finally,  FIG. 5  shows assembly  540 , comprising of connector  541 , connector holder  510  and profile gripper  520 , which are assembled together with profile  530 , to make sturdy assembly  540 . Holes  512  of the connector holder and holes  522  of the profile gripper coincide, and through them the screws of the various connectors, shown in  FIG. 4  are inserted. The gripping format of the profile gripper is designed as such in order to accommodate various widths of stone. While in stone-plaster wall  100  ( FIG. 1 ), for instance, both the connector holder and the profile gripper are used together, in stone-stone wall  210  ( FIGS. 2A-2B ), for instance, only profile gripper  520  is used (without connector holder  510 ). 
         [0145]      FIG. 6  is a simplified flow chart  1000  of a method for constructing a double-sided stone-plaster coated wall  100  described in  FIG. 1 ; in accordance with some embodiments of the present invention. 
         [0146]    In a first assembling step  1002 , a plaster board is positioned. Prior to this step, the following optional steps may be performed onsite: 
       Determining Stone&#39;s Positions: 
       [0000]    
       
         
           
             a. Numbering stones  101  upon their arrival to the construction site, 
             b. Determining their locations on the wall.
 
In step  1002 , the internal plaster surface is positioned by:
 
             a. drilling plaster board  102 , 
             b. attaching to it a support frame  103 , using a stone-plaster connector (SPC)  107 , connector holder  108  and profile gripper  109 , described in further detail in  FIGS. 4-5 , respectively, and anchoring support frame  103  to the floor, 
             c. optionally attaching thermal insulation panel  106  to plaster board  102 , while puncturing it to create holes  113 , using plaster board  102  as a model, and then enlarging holes  113  by a drilling cup, 
             d. attaching additional support frames to plaster board  102  using stone-plaster connectors, connector holders and profile grippers, and anchoring them to the floor as well, 
             e. assembling the lowest row of stone-plaster connectors  107  to plaster board  102 , using connector holders  108 , while the sharp ends of the pins of the stone-plaster connectors  115  are vertical,
 
In a second assembling step  1004 , a row of stones is assembled opposite to the plaster surface. This step may entail, for example, the following sub-steps:
 
             a. Drilling each stone  101  of the first row, 
             b. Optionally applying sealant to the surfaces forming the gaps between neighboring stones, 
             c. Positioning each stone against plaster board  102  and insulation panel  106 , while inserting pins  115  of the lowest row of stone-plaster connectors into the holes located at the bottom of each, and 
             d. Optionally applying sealant on the back of the stones row. 
           
         
       
     
         [0158]    In a third assembling step  1006 , horizontal reinforcing rods  110  are assembled between the two boards assembled in the previous two steps, respectively. Step  1006  comprises the following typical sub-steps:
       a. placing a horizontal metal rod  110  at each of the two “horizontal canals”  118 , created by the row of stone-plaster connectors  107 ,   b. assembling an additional row of stone-plaster connectors  107  to plaster board  102 , using connector holders  108 , and inserting their pins into the upper holes of the row of stones,   c. Placing additional horizontal metal rod  110  at each of the two “horizontal canals”  118 .       
 
         [0162]    In a checking step  1007 , the height of the wall is examined as to whether or not it reaches the desired height. If the height hasn&#39;t reached the desired one, then we proceed to the additional checking step  1009 . In checking step  1009 , the height of the row to be assembled is compared to the plaster board height. If it is less than the plaster board height, then steps  1004 ,  1006  and  1007  are repeated. The following sub-steps may then be performed:
       a. drilling an additional row of stones and placing it on top of the previously assembled one,   b. assembling an additional row of stone-plaster connectors  107  to plaster board  102 , using connector holders  108 , and inserting their pins into the upper holes of the row of stones,   c. placing an additional horizontal metal rod  110  at each of the two “horizontal canals”  118 ,   d. optionally adding any required service conduits,   e. Cementing spaces  114  between any neighboring stones, including adding adhesive sealant in spaces  114 .       
 
         [0168]    These sub-steps are repeated until the height of the row to be assembled exceeds the height of plaster board  107 . If it does, then step  1002  is added to the assembling process. 
         [0169]    This iterative process takes place repeatedly while adding rows of plaster boards and insulation panels at the internal side of the wall, and rows of stones at the external side of it, and placing horizontal metal rods and service conduits in between them, until the desired height of the wall is finally reached. Then, vertical reinforcement rods  111  are threaded through “vertical tunnels”  119 , created by the vertically aligned loops of stone-plaster connectors  107 , to obtain metal reinforcement grids  160 . At the end of this assembling process, a hollowed wall is obtained, which is supported vertically by a row of support frames and is composed of layers: plaster board layer, insulation panel layer, internal metal grid layer, external metal grid layer, and a stones board layer. 
         [0170]    In a filling step  1010 , the final form of the wall is produced by:
       a. pouring concrete  170  into the wall, while using vibration, and waiting for it to harden,   b. dismantling the profile grippers, the support frames, and the connector holders, and   c. Driving the screws of the stone-plaster connectors into the plaster board.       
 
         [0174]    The stone-plaster connectors remain in the wall forever to fasten both the plaster boards and the stone to the cast wall. 
         [0175]    At this stage, a stone coated wall on the outside and plaster coated on the inside, is obtained, which is optionally thermally insulated. The internal aspect of the wall is ready for painting while the external aspect is fully completed. 
         [0176]    Although  FIG. 1  shows a flat wall, this method includes rounded walls as well. In the latter cases, both the plaster board and the connector holders need to be rounded in the necessary curvature and sufficiently short and appropriate stones need to be used. Note that in such cases the distances between the stone holes and those of the plaster board are different. 
         [0177]    It should be understood that many permutations and variations on this method are possible and are deemed to be within the scope of this invention. 
       Preferred Construction Methods and Procedures for Cast Structures 
     Construction of Stone-Plaster Wall 
       [0178]    The construction of stone-plaster wall, in accordance with the present invention, is described in further detail in  FIG. 1  and  FIG. 6 .  FIG. 1  describes the components of the wall, including the connectors and elements used to successfully assemble the wall.  FIG. 6 , however, describes a flowchart, which describes step-by-step the sequential procedure of carrying out the mission of assembling and building a stone-plaster wall. 
       Construction of Plaster-Plaster Wall 
       [0179]    The construction method of a plaster-plaster wall, according to the invention, as described in wall  240  in  FIG. 2 , is performed similar to that of a stone-plaster wall, and it includes the following typical steps:
   1. establishing internal plaster surface  242  as described in the stone-plaster wall construction, using plaster-plaster connectors (PPC)  243 , described in further detail in  FIG. 4  connector  420 , instead of SPC  107  (in  FIG. 1 ),   2. establishing the external plaster surface  241  in a similar manner, and adding horizontal metal reinforcement rods and any required service conduits,   3. assembling the rest of the wall by adding additional plaster boards, Plaster-plaster connectors, metal rods and service conduits,   4. The final construction of the wall is performed as in the stone-plaster wall.   5. Although  FIG. 2  shows a flat wall, this method includes rounded walls as well. In the latter cases, the plaster boards, the metal rods and the connector holders can be rounded in the necessary curvatures. Note that in such walls the horizontal distances between neighboring holes in one plaster surface are different from those of the other surface.   
 
       Construction of Stone-Stone Wall 
       [0185]    The construction method of a stone-stone wall, according to the invention, as described in  FIG. 2  in wall  410 , is performed similar to that of the stone-plaster wall, and it includes the following typical steps:
       1. determining stones&#39; positions, using the computer program,   2. positioning the first drilled internal row of stones  212  on top of a row of stone-stone connectors (SSC)  413 , described in  FIG. 4  connector  430 , while the sharp ends of the connectors&#39; pins are inserted into the holes, located at the bottom of the stones, and the external pins are positioned at the external front of this wall,   3. similarly, connecting the external stone row  411  to stone-stone connectors  413 , and then placing a pair of horizontal metal rods on top of stone-stone connectors  413 , and connecting to them vertical support frames, using profile grippers,   4. assembling the rest of the wall by adding rows, stone-stone connectors, horizontal metal rods, service conduits, and, at the end, threading vertical metal rods,   5. The final construction of the wall is performed as in the stone-plaster wall.   6. Although  FIG. 2  shows a flat wall, this method includes rounded walls, provided that sufficiently short and appropriate stones are used, and the appropriate distances between stone holes are determined.       
 
       Construction of Partially or Fully Uncoated Wall 
       [0192]    The partially and fully uncoated walls include 3 types of walls as follows (see  FIGS. 2A-2B ):
       a. stone-concrete (concrete means uncoated) wall (e.g., wall  220 ),   b. plaster-concrete wall (e.g., wall  250 ), and   c. concrete-concrete wall (e.g., wall  260 )       
 
         [0196]    The construction method of a stone-concrete wall, according to the invention, is performed similar to that of a stone-plaster wall, except that here stone-concrete connector  223 , depicted in  FIG. 4  connector  460 , is used. 
         [0197]    In this case, the plaster board is typically a thin plywood, plastic board or sheet metal, which is removed together with the connectors&#39; screws that fasten it, after the concrete hardens. 
         [0198]    The construction method of a plaster-concrete wall, according to the invention, is performed similar to that of a stone-plaster wall, except that here plaster-concrete connector  453 , described in further detail in  FIG. 4  connector  450 , is used. In this case, the stone plane is replaced here by a thin plywood board, a plastic board or a sheet metal, which is removed, together with the connectors&#39; screws that fasten it, after the concrete hardens. 
         [0199]    The construction method of a concrete-concrete wall, according to the invention, is performed similar to that of a plaster-plaster wall, except that here, concrete-concrete connector  463 , described in further detail in  FIG. 4  connector  440 , is used. In this case, the plaster boards on both sides of the wall are typically thin plywood, plastic board or sheet metal, which are both removed, together with the screws of the connectors, after the concrete hardens. 
         [0000]    Construction of Wall with Window/Door
       1. assembling the wall as described in the stone-plaster wall  230  in  FIGS. 2A-2B  construction, until the height of the window base is reached,   2. establishing the internal plaster boards at the window level,   3. drilling the stones and assembling them using stone-plaster connectors (SPC)  233 , connector holders and, when necessary, profile grippers,   4. drilling and assembling the right-angle stones  235  at the sides of the window frame lintel  239 ,   5. when the top of the window frame lintel is reached, a drilled stone  237  is assembled, and two or more metal rods  258   a  are placed on top of it, together with a thin layer of concrete, e.g. 10 cm, to strengthen stone  237  together with it&#39;s neighboring stone  235  for withstanding the weight of the poured concrete above it in the future,   6. Building the rest of the wall as described in the stone-plaster wall construction.   7. When a door frame lintel is used, then the door frame lintel is positioned on the floor, and the assembling procedure is the same.   8. When plaster-plaster, or concrete-concrete, or plaster-concrete wall is built with window/door aperture, then long marble stones are added to the sides of the window/door aperture in order to fully frame the lintel by stones.       
 
       Construction of Ceiling 
       [0208]    The construction method of plaster or stone coated ceiling, in accordance with some embodiments of the present invention, is described herein below. 
         [0209]    The construction process of plaster coated ceiling  280 , described in  FIGS. 2A-2B , includes the following typical steps:
   1. Positioning jacks  231 , profiles beams  232  and right-angle profiles  284 ,   2. Drilling plaster boards  281 , positioning them above profiles  284  while their connection  281   a  is on top of single profile  284 , and taping connection  281   a  by tape  281   b,      3. if necessary, placing thermal insulation boards  282  above plaster boards  281  and creating large holes  287   c , using drilled plaster boards  281  as a model,   4. When necessary, adding bricks  285 , metal reinforcement rods and service conduits  287 ,   5. Typically connecting ceiling-plaster connectors  283 , together with connector holders at the bottom (not seen),   6. Pouring concrete with vibration,   7. After the concrete hardens, removing the connector holders and tightening the screws of ceiling-plaster connectors  283 , and   8. Removing jacks  231 , profile beams  232  and right-angle profiles  284 .   
 
         [0218]    The construction process of stone coated ceiling  290  is similar to that of plaster coated ceiling  280 , except that here, coating stones  291  are used. The stones are drilled and assembled in a similar way as stones  101  in  FIG. 1  are drilled and assembled. Also here, ceiling-stone connectors  293  are used, in stead of ceiling-plaster connectors  283 , together with connector holders (or maybe profile grippers). Note that here, when removing the connector holders, the screws of connectors  293  are removed as well. 
       Wall-Ceiling Connection 
       [0219]    Wall-ceiling connection requires that the metal rods and the poured concrete of the ceiling would be on top of the wall as a one complete continuum. It is also required that this concrete would not be spilled externally beyond the wall. Therefore, an additional row of stones needs to be assembled beyond the height of the wall, which serves as a “peripheral stone rail” for preventing the concrete of the ceiling, when poured, from being spilled. This is performed in the following typical steps (see  FIGS. 2A-2B ):
       1. threading a short solid sleeve  267  through each vertical profile of the support frames, to protect it from the concrete,   2. assembling horizontal “ceiling profile rail”  265  to each vertical profile,   3. connecting the “ceiling stone rail” to the “peripheral profile rail”  243 , using both stone-plaster connectors (SPC) and profile grippers  266 ,   4. If a plaster-plaster wall is built, then the same method is used, except that, instead of a “ceiling stone rail”, the external plaster board is used together with plaster-plaster connectors (PPC).       
 
       Stone Coating of an Existing Wall 
       [0224]    In order to coat wall  270  by stones  272  (see  FIG. 2B ), stone anchoring net  271  is first anchored to wall  270 , using bolts  274  and discs  275 . Wedges  276  are used to help level net  271 . Then, stones  272  are drilled and assembled on the wall in a similar way as assembling the stones in wall  100 , described in  FIG. 1 , except that here, stone-net connectors  273  are used. Note that typically here the concrete is poured between stones  272  and wall  270  after assembling fewer rows of stones (e.g. one or two) and not necessarily after reaching the top of the wall. Also note that once net  271  is positioned at the required orientation (typically vertical), stone-net connectors  273  make sure that all stones  272  are mutually co-planar as desired. 
       Construction of Plaster Coated Column 
       [0225]    The construction method of a plaster coated column, according to the invention, as described in  FIGS. 3A-3B , includes the following typical steps:
       1. Cutting and drilling all plaster boards  341 ,   2. positioning the plaster boards, except one, and attaching them to support frames  347  using plaster-plaster connectors (PPC)  342 , connector holders  343 , and, when necessary, profile grippers, and anchoring the support frames to the floor,   3. fastening reinforcement metal rods  345  and metal rims  345   a  to the plaster-plaster connectors through the sides of the column where the plaster board hasn&#39;t been assembled, and then assembling this missing plaster board, using connector holders  343 ,   4. Pouring concrete and, after it hardens, dismantling the supporting elements as described in the construction of a stone-plaster wall.   5. For wider columns, more than one column of plaster-plaster connectors needs to be assembled.   6. Although  FIGS. 3A-3B  shows a rectangular column, this method includes columns of various polygons. It also includes circular and elliptic forms. In the latter cases, the plaster boards, the metal rims and the connector holders should be rounded in the necessary curvature.       
 
       Construction of Stone Coated Column 
       [0232]    The construction method of a stone coated column, according to the invention, as described in  FIGS. 3A-3B , includes the following typical steps:
       1. cutting stone  331  to the proper sizes and drilling them,   2. assembling the bottom stone frame using stone corner connectors (SCC)  332 , described in further detail in  FIG. 4  connector  4120 , and fastening it to the support frames, using profile grippers, when necessary, then placing each metal reinforcement rim  335  on top of the SCCs, such that each cress of the SCCs (see  FIG. 4  connector  4120 ) is located inside the rim,   3. repeating step  2  iteratively while filling the spaces between stones with cement and adhesive sealant, until the height of the column is reached,   4. threading each vertical reinforcement rod  334  through the loops of SCCs  332 ,   5. pouring concrete, and after in hardens, dismantling the support frames,   6. Although  FIGS. 3A-3B  shows a rectangular column, this method includes columns of various polygons and circular and elliptic forms, provided that the proper stone shapes are used.       
 
       Construction of Partially or Fully Uncoated Column 
       [0239]    The construction of partially or fully uncoated column requires the replacement of the plaster boards (or stones) of the desired uncoated sides by plywood boards and, correspondingly, using the appropriate connectors that have concrete heads at the desirable uncoated sides of the column. Finally, pouring the concrete in the same manner as previously described, and after it hardens, removing the plywood boards to obtain uncoated sides of the column as desired. 
       Construction of Beams 
       [0240]    The construction process of a plaster coated beam, in accordance with the embodiment of the present invention, is performed in the following steps (see  FIGS. 3A-3B ):
       1. Erecting jacks, placing profile beams on top of them, and positioning right-angle profiles in the appropriate configuration, using the same principles described in ceiling  280 , described in  FIGS. 2A-2B ,   2. drilling the bottom plaster board, placing it on top of the right-angle profiles, and adding plaster-ceiling connectors, together with their connector holders,   3. erecting profile frames  355 , similar to that when building wall  100  in  FIG. 1 ,   4. assembling drilled plaster boards  351 , using plaster-plaster connectors  352  in a similar manner as assembling plaster-plaster wall, and adding the metal reinforcement rods,   5. pouring the concrete, and adding additional boards on top of the beam, if necessary,   6. After the concrete hardens, removing the support frames, the connector holders, the jacks, and the profiles, and screwing the screws of the various connectors into the plaster boards.       
 
         [0247]    The construction process of a stone coated beam, in accordance with the embodiment of the present invention, is performed in a similar way as the plaster coated beam is done. However, coating stones as apposed to, plaster boards are used. And, of course, the bottom stones are drilled and assembled in a similar manner as stone coated ceiling  290  (described in  FIGS. 2A-2B ), together with stone-ceiling connectors. The side stones are drilled and assembled in a similar manner as stone-stone wall  210  is built (see  FIGS. 2A-2B ). 
       Abbreviations 
       [0000]    
       
         SPC—stone-plaster connector 
         PPC—plaster-plaster connector 
         SSC—stone-stone connector 
         SCC—stone corner connector