SEGREGATED SLAB STRUCTURAL PRODUCTS,PROCESS AND APPARATUS FOR MAKING SEGREGATED SLAB STRUCTURAL PRODUCTS,AND STRUCTURES INCORPORATING SUCH PRODUCTS

Abstract: Plurality of structural products comprising segregated slabs, (21, 23) process of making such structural products, and apparatus for performing such process of making such products and structures incorporating such products. The product comprises a plurality of slabs (21, 23) connected to each other only by an array (25) of steel bar members extending therebetween and firmly attached thereto, whereby the slabs are movable relative to each other in direction transverse to the length of said bar members, so that many undesirable yet usually developed stresses and strains and failures developed in conventional reinforced concrete structures are obviated, and a light, strong, low-cost, thermal insulating structure is provided. The process of manufacture of the segregated slab product provides for rapid reliable low-cost manufacture of the structures shown and utilizes the spaces provided in the structures made for location and operation of mold forming apparatuses. The static structures incorporating the segregated slab products minimize the effect of thermal stress and strains on the separate concrete-containing components thereof.

Description: Description Segregated Slab Structural Products, Process and Apparatus for Making Segregated Slab Structural Products, and Structures Incorporating Such Products Technical Field The fields of invention to which this invention per¬ tains are static structures and molds therefor. Background Art The prior art of composite concrete structures has utilized spaced apart slabs of concrete, but such masses have not been free of other masses of concrete joined to the spaced apart concrete masses such as- in U.S. Patents 3,932,082; 1,828,907; and 847,454 with a resultant lack of freedom of movement of the spaced apart masses of concrete and resultant development of strains and stresses due to change in dimensions of the concrete during curing as well as due to temperature differentials during use. Also mini¬ mum concrete covering of steel is common practice and direct exposure of steel to spaces between concrete masses is de¬ plored by authorities in the field. Disclosure of Invention Composite structures of segregated slabs joined only by steel members in interslab spaces provide for relief of strain and avoidance of stresses as might usually cause con¬ crete cracks and failures as well providing a light-weight product, low in cost of manufacture and installation and with excellent thermal properties in use. A process and interim support apparatus to make the composite structure and utilizing the space between th.e concrete masses to lo¬ cate such interim support apparatus is provided and struc¬ tures utilizing the product, particularly for its thermal properties as well as light weight are developed. " ?I Brief Description of Drawings FIGURE 1 is a perspective view of an assembly of slab and bars formed according to this invention. FIGURE 2 is an exploded perspective view of a set o components prior to assembly use to form an assembly as i FIG. 1. • FIGURE 3 is a perspective view of a spacer unit used i the formation of the apparatus of FIG. 1. FIGURE 4 is a plan view diagrammatically showing a mol assembly used in the formation of the apparatus of FIG. 1. FIGURE 5 is a side view of molds during assembly of a apparatus as in FIG. 1 and is diagrammatic. FIGURE 6 is a perspective view of a mold used for form ing a reinforced steel slab for assembly according to thi invention using prestressed wires or rods. FIGURES 7, 8 and 9 show steps in the formation of a apparatus according to this invention as shown in FIG. 1. FIGURE 10 is a detail view of the assembly 104 shown i FIG. 3 and in FIG. 13. FIGURE 11 is -a diagrammatic sectional view along plan 11A-11A of FIG. 13 during making of the apparatus 20. FIGURE 12 is a phantom view showing internal structur of a modification of the assembly shown in FIG. 1. FIGURE 13 is a diagrammatic vertical longitudinal sec tion along the section 13A-13A of FIG. 11. FIGURE 14 is an end view along the direction of th arrow 14A of another embodiment of apparatus, shown in FIG 15. FIGURE 15 is a perspective view of the apparatus show in FIG. 14. FIGURE 16 is a diagrammatic vertical transverse sec tional view showing another embodiment of apparatus in « portion of a completed structure. FIGURE 17 is a diagrammatic vertical transverse sec tional view of another embodiment of apparatus according t this invention. FIGURE 18 is a plan view as seen along direction o arrow 18A of FIG. 19 of an embodiment as shown in FIG. 20. O FIGURE 19 is an end view of a structure shown in FIGS. 18 and 20 as seen along direction of arrow 19A of FIG. 18. FIGURE 20 is a side view of an embodiment of apparatus as seen along direction of arrow 20A of FIG. 19. FIGURE 21 is a composite view showing a vertical sec¬ tion view of a building structure with components as shown in FIGS. 1, 16 and 20. Best Modes for Carrying Out the Invention The description is set out under the following head- ings: (A) The segregated slab product; (B) apparatus for forming the segregated slab product; (C) process of forma¬ tion of the segregated slab product; (D) structures incor¬ porating the products. A. The segregated slab product 20 is an assembly of slabs comprising a first rigid slab 21 comprising concrete and reinforcing steel, a second rigid slab 23 comprising concrete and reinforcing steel, a space 22 therebetween, and an array 25 of steel bar members. The first and second slabs are spaced away from each other. The first slab ex- tends between a first plane 31 and a second plane 32, said first and second planes parallel to each other, and the space 38 between said first and second planes is occupied by the rigid material, comprising concrete and steel forming the slab 21. The second slab extends between a third plane 33 and a fourth plane 34. The third and fourth planes are parallel to each other and spaced away from each other. The space 39 between said third and fourth planes is occupied by the rigid material comprising concrete and reinforcing steel forming the slab 23 as shown in FIGS. 1 and 12. The first and fourth planes, 31 and 37, are spaced apart from each « other and parallel to each other and the second and third planes, 32 and 33, are located between the first and fourth planes, 31 and 34, with the second plane 32 located be- tween the third and first planes, 31 and 33, and the third plane 33 located between the second and fourth planes, 32 and 34. OMPI - " - The second and third planes 32 and 33 are spaced a from each other by an interslab space, 22 and a system array 25 of like steel bar members show as 26-29, 36-38, 48, 56, 57 and 66-69 in FIG. 1 extends from the slab ma ial of top slab 21 (between the third and fourth planes the slab material of bottom slab 23 (between said first second planes) . Each of the steel bar members, as 26-29 and 36-38, 48, 56, 57, and 66-69 of the array has an upper imbe portion 41 imbedded in the first, upper (as shown in 1) , slab and firmly attached thereto, a lower imbedded tion 42 imbedded in the second, lower, slab and firmly tached thereto, and (σ) an intermediate portion 42 loc between the second and third planes and directly expose the space 22 between the slabs 21 and 23, as shown for member 26 in FIG. 12. As shown in FIG. 1 the opposite edges of the upper lower slabs 21 and 23 have stepped and portions. Thus, edge 151 of the upper slab 21 has a vertical flat end tion 153 that extends only a portion of the total heigh thickness of that slab 21; that portion, 153, is contin with a middle horizontal extending flat portion, 154, that horizontal end portion, 154 is continuous with the wer (as shown in FIG. 1) end or edge portion 155. The 152 opposite to edge 151 of the upper slab 21 has a vert flat end portion 156 that extends only a portion of the tal height or thickness of that slab 23, that portion, is continuous with a middle horizontal extending flat tion, 157, and that horizontal end or edge portion, 15 continuous with lower (as shown in FIG. 1) end portion The opposite edges of the lower slab 23 have stepped portions. Thus, one edge 161 of the slab 23 has a vertical end portion 163 that extends only a portion of the t height or thickness of that slab 23; that portion, 163 continuous with a middle horizontal extending flat port 164, and that horizontal end or edge portion, 164, is tinuous with lower (as shown in FIG. 1) end por The edge 162 opposite 161 on the lower slab 23 has an upper flat end portion 166 that extends only a portion of the total height or ' thickness of that slab 23; that portion, 166, is continuous with a middle horizontal extending flat portion, 167, and that horizontal end portion, 167 is con¬ tinuous with upper (as shown in FIG. 1) end portion 168. Portions 156, 158, 166 and 168 are vertical. Each of the bar members of array 25 as 26-29 is arrayed in one of several different straight rows or lines, as row 146, and all the other members of array 25 are also arrayed in other rows, as row 147 for members 46-48 and row 148 for members as 66-69. These rows are parallel to each other and spaced apart from each other by the same distance measured in direction transverse to the length of each row. Each of the bar members in a line, or row as 26, 27, 28 and 29, part of which are shown in FIG. 1, may be held firmly together and in line by rigid straight horizontally extending end pieces as 45 and 47. The imbedded end pieces 45 and 47 are rigid rods and maintain the rigid members of the row of mem- bers as 26-29 in line during assembly to form the apparatus as 20 and also provide for bonding of the members 26-29 to the concrete and also provide bearing or support surface for the members as 26-29 in masses 21 and 23 when the concrete in such masses has set. Such portions have bends depending on thickness of the bar used, (such as set out in Table 10 of Dunham "Theory and Practice of Reinforced Concrete" McGraw Hill, 4th Edition, p. 608) to avoid undesirable stresses in the steel. Such portions 45 and 47 are located in the mass of concrete while forming the slabs 21 and 23 and on completion of the casting process are firmly imbedded therein. Heavy steel wire mesh mats as 63 and 64 (as in ASTM designations A-184 and A-185) are also provided for similarly imbedding the concrete masses 21 and 23 respec¬ tively. The members 45 and 47 and also the mats 63 and 64 as shown in FIG. 2 reinforce the mass of concrete in which imbedded. The array 25 of bars is formed of a plurality of rigid members, as bars 26-29, 36, 46 and 56 as shown in FIG. 1 each of which bars extends from within: the first lower 2 slab, through the inter slab space 23 to within the secon slab 21. The imbedded portion of each bar member, as por tion 41 of bar member 36 (FIG. 11) extends parallel to th first and second planes 31 and 32 although the spacer por tion 42 of each bar member, as 26 extends transversely t " the planes 31, 32, 33 and 34 and the imbedded portion 43 o each bar member as 26 extends parallel to the third an fourth planes 33 and 34. The depth of immersion of each of the bend portions 4 and 43 of each of the bar member into the respective slab t in which imbedded, as 21 and 23 respectively is adequate fo bonding of such member to the slabs 21 and 23 respectively The length of bar needed to provide adequate anchorage i set out in codes and also at page 591, Table 4, of "Theor and Practice of Reinforced Concrete" McGraw Hill, 4th Edi tion, 1966, by C. . Dunham. Also the. total cross sectional area of the totality o the bent portions, as 41 and 43 of array 25 parallel to th planes 31-34 is adequate to avoid exceeding the compressiv strength of the conrete to which attached in view of th stresses to which those bars are to be subjected. Whil such dimensions will vary such calculations are well withi the ability of the designer of usual skill and expressed i fomulae provided by standard civil engineering textbooks for example formulae exprssed in the Hewlett Packard tex entitled "Hewlett Packard HP 41C. Users' Library Solutions Civil Engineering", catalogue No. 00041-90089 (give pro vision for programming such calculation) and also is avail able to determine for loads on structural steel column using the American Institute of Steel Construction Formul (1961) whereby the allowable column load (from formula herebelow is readily determined for structured of differen sizes and varied loads, also the required moment of inerti (from formula II herebelow) (in view of that the vertica column portions as 42 are firmly held by the portions 42 an 43 imbedded in the slabs as 21 and 23) is also readil determined. I - p allow = A D f! " (VK) 2 /2 C 2 ]/m for L/k < C P allow = A(1.0273 x 10 12 N/m 2 )/(L/K) 2 for C<L/k < 200 = 5/3 x 3(L/k)/7C - [ (L/k)/2C] 3 p max = p allow Definitions: P allow is the allowable load; P max is the maximum load the column could carry; A is the area of the section; L is the length of the column; K is the minimum radius of gyration of the column cross section; I is the minimum moment of inertia of the cross section; D y is the yield point of the steel; E is the modulus of elasticity of steel. II. The amount or section area of rods as 42 needed to provide the moment of inertia to resist compressive buckling would be no greater than (a) p = ττ 2 El 4L 2 where P is the critical buckling load; E is the modulus of elasticity; I is the minimum moment of inertia; and L is the length of the member 42. A horizontally (in FIG. 12) extending rigid steel rod member as 191 is attached to each of the vertically extend¬ ing bar members 26-28 in the same row as in row 146, and like transverse rod members as 192-195 are attached to the vertical members in space 42 in all of the other like and parallel rows, as row 14, 147 and 148, respectively of array 25. Such transverse members serve to transfe.r stresses of displacement of each, as 27, of those bar members transverse to their length to adjacent bar members, as 26 and 28, and so resist displacement for a given volume and weight of such vertical members and so provide more strength to resist com¬ pression transverse to the length of the slabs as 21 and 23 for a given weight or cross section of steel bars a - 8 - B. The apparatus 20 is formed by manipulation of co crete in liquid form, reinforcing bars, and the array of b members 25 using a mold assembly, 50, and a plurality slab mass spacing and support units as 58 and 59. The mold assembly 50 comprises a plurality of mo frames assemblies as 51 and 52,. and mold frame spacers as and 54, the spacers as 53 and 54 are rigid bars that suppo the mold frames in a spaced apart relation to each othe whereby a mold frame assembly space 55 is provided betwe the bottom on one, the upper, mold frame assembly 52 and t top of the other, lower, mold frame 52. The upper mold frame assembly, as 51, comprises series of rigid form walls or boundary plates as 71-74, ea of which walls or plates is connected at one end to a slid as 75-78 respectively, that slides over another mold wal as shown in FIG. 4; one of the slides, as 78, is connecte to an opening latch as 79 that allows the form to be clos for casting or permit separation by opening the form and a lowing it to be removed from the casting after the casti is finished. The upper form walls surround the perimeter o the upper casting area, 80, but the top and bottom of th casting area in the upper mold assembly, as 51, are open. The bottom mold frame assembly as 52, comprises series of rigid form walls or boundary plates, as 81-84 like 71-74 respectively, and slides as 85-88, like 75-7 respectively, and has an opening latch like 79. The lowe form walls surround the perimeter of the lower casting area 90, and a casting surface or floor member, 91 is located a the bottom of the lower casting area, and firmly yet releas ably attached to the walls 81-84. Each of the slides 75-78 firmly yet releasably holds vertically extending telescoping connecting bar sleeve, a 95-98 and each of the slides 85-88 similarly holds a sleev for the telescoping connecting bars, as shown by sleeves 9 and 94 on slides 85 and 86 in FIGS. 2, 3 and 5. A rigid spacer bar 53 fits into sleeves 93 and 95 and spacer bar 54 fits into sleeves 94 and 96. Those bars ar of uniform transverse cross section and firmlv held in thos sleeves. Like bars 253 and 254 in sleeves 77 and 78 on the other slides are adjustably yet firmly located in those sleeves, whereby a mold frame space 55 of controlled height is provided between the mold frame assemblies as 51 and 52. Figure 6 shows a form 170, generally like 52 for a top slab as 21 and with all four sides thereof, 171-174, pro¬ vided with outer stepped edge portions as 176 and 177 ex¬ tending beyond inner edge portions as 178 and 179 on all adjacent form sides as well as for forming stepped edges on opposite sides only as shown in FIGS. 1 and 2. Such form 170 is provided with hinged slides as 75-78 provided for form 51 and is also provided with inlet holes as 181-188 that permit that form to hold reinforcing members or pre- stressed reinforcing members, as 191-199 for incorporation into the concrete mass formed within such mold. A similar mold is provided for a lower slab as 23 the holes as 181-184 • provide for bearing reinforcement members or applying ten¬ sion in reinforcement members located near to the top of the finished slab. Holes 185-188 provide for applying tension to pretensioned members near the bottom of the slab or sup¬ porting reinforcement members near the bottom of the finish¬ ed slab. The concrete (49) used in forming the slats as 21 and 23 and other slabs herein disclosed as shown in FIGS. 14, 15, 16 " , and 20 is a type II (ASTM C-150) with low water- cement ratio, with 4,000 p.s.i. strength at 28 days with 3/4 inch maximum size aggregate. Each of the slab mass support and spacing units, as 58 and 59 comprises a first, rigid, upper, .casting surface and casting support unit 101, a second, lower, support and bear¬ ing surface unit, 102, a set 103 of expansion lir. s, and an expansion link set actuating assembly 104. 4 The upper casting surface and surface support unit 101 comprises a rigid steel T-sectioned top plate III having a smooth upwardly facing top surface 112 with a rectangular outline and a top plate support flange 113. The plate 111 and plate support flange are firmly joined together as a rigid "T" shaped section with plate on top and support therebelow as shown in FIGS. 3 and 11. The lower support and bearing surface unit 102 com rises a rigid steel T-sectioned bottom plate 121 having smooth downwardly facing bottom surface 122 and an upward extending guide flange 123 firmly joined together. The set of links (103) is formed of a plurality of li expansion link sets, as 106, 107, 108 and 109, each of whi joins the downwardly extending upper flange and the upward extending lower flange of the plates 101 and 102. Each s of expansion links as 107 comprises an upper link, 131, p votally joined to the upper flange at an upper link pin 13 firmly joined to the upper flange, and a lower link, 133 pivotally joined to the lower flange at a lower link pi 134, firmly attached to the lower flange. The lower end the upper link and the upper end of the lower link .ar pivotally joined at a center link pivot pin 135. The cent link pivot pin, as 1-35, of one set, as 107 and the pin, 136 of another set of links, as 108, attached to the same uppe flange and lower flange of the casting surface and suppor unit, as 58, are joined by a rigid control link, 110. Th lower flange 123 is firmly connected to a lower rigid shaped control arm 129 and the upper flange 113 is pivotall connected at actuator pin 124 to an upper control arm 119 Actuator links 137 and 138 are like links 131 and 133 i size and between-pin distances and are connected by a pi 139 (like pins 135 and 136) . Pin 139 is connected to lin 110. The link set actuating assembly 104 comprises an uppe rigid control arm 119, a lower control arm 129, pivotall connected at pin 125, and an adjustable arm operator 131 a shown in FIG. 10; the operator 131 comprises a sturd threaded bolt 142 and nut 143 and spring 144; the bolt i firmly yet slidably located in the holes or journals there for in the arms 119 and 129. A pivot pin 124 is held bot in arm 119 and flange 113. Arm 129 is firmly fixed t flange 123. A long-armed wrench applied to the nut 143 an turning the nut on the bolt 142 in one direction provide for adjustably raising the upper casting surface and suppor C unit 101 relative to the lower support unit 102 while paral¬ lel thereto: turning the nut 143 in the opposite direction provides for adjustably lowering the upper casting surface relative to the lower unit 102 while the upper surfaces and lower surfaces of units 101 and 102, respectively, are pa¬ rallel to each other. There may be a like link actuating assembly 105, (like actuating assembly 104) , at each ends of all units as 58. Also there may be more than two like sets of links such as In * k sets as 106 and 107, as shown in FIGS. 3 and 13. FIG. 1 is drawn in perspective to diagrammatically il¬ lustrate the rectilinear arrangement of straight line array of the vertical portions, as 42, of the rows of bar members, as 26-29, 36-39, 46, 48, 56, 57, 159 and 66-69. One of the rows is indicated in FIGS. 9 and 11 and 12 by referent num¬ ber 146 and 147. The diameter or thickness of the bars as 26-29 and their spacing along the rows is chosen • to provide, in view of the compressive strength of the concrete used and usual safety factor adequate cross-sectional area to resist compressive stress applied to the finished assembly 20. The length of the slab mass spacer and support units as 58 and 59 (and other as 60 used to form assemblies as 20) is great relative to their width as 145 and the upper surface thereof, as 112, is rectangular in shape so as to fit read- ily in the space between the rows as 146 and 147 of vertical portions as 42 of the bar members, 26-29 and 36-39 and 46- 49 in the interslab space as 22. The ready reduction of the height of the upper surface, as 112, of the slab mass spacer and support units as 58 by adjustment of the actuating as- semblies as 104 provides for ready removal of the units as unit 58 and 59 after the mass of concrete and reinforcement, as 21, has set. C. The process for forming an overall rigid composite segregated slab product as 20 is illustrated diagrammatical- ly in FIGS. 7-9 comprises the steps of (a) pouring a first mass of concrete in a mold as 52 in the form of a first flat slab as 23 having a width and length very much larger than its thickness and then (b) forming a floor above and spaced C rl by space as 55 from the top of the first slab while (c) sup porting a rigid array of bars as array 25, in which arra each of the bars extends vertically f om within the firs lower mass 23 to above the floor surface formed by the to surfaces, as 112, of each of the slab mass support and spac ing units as 58, of a large member of such like units, as 58 59 and 60, as shown in FIG. 9, then (d) pouring a second con crete mass as shown in FIG. 9 on said floor to form a secon slab, as 21 and so attaching one lower end as 43 of eac of the bars of the array of bars, as bar 26, to one of sai slabs as 23 in which imbedded and another, upper end as 4 of each of such bars as 26 to the other -of said slabs as 21 D. In Figures 14 and 15 another segregated slab embodi ment, 220 is shown. Embodiment 220 is formed of an uppe slab 221, a middle slab 223, and a lower slab 224, with a upper interslab space 222 between slabs 221 and 223 and lower interslab space 224 between slabs 223 and 225. Th slabs 221, .223 and 225 are firmly held in position relativ to each other by ' rod arrays 226 and 227; each rod array 22 and 227 is composed of an array of steel bars like array 2 in embodiment 20 shown in Figure 1. The array 225 is com posed of rigid like straight lines or rows, as 231, and 23 of bar members as 228, 229, and 230 in row 231. Each mem ber, as 221 is like member 26 in row embodiment 20 and eac row 231, 232, 233 is like the rows.146, 147 and 48 in embod iment 20. Array 227 is composed of several like rows a 234, 235, 236, each like rows 231, 232, and 233 respective ly. Rows 231 and 234 are co-planar ' and rows 232 and 235 ar co-planar and rows 233 and.236 are co-planar. The flex ibility of the bar members permits movement of slab 223 rel ative to slab 221 and the flexibility- of array 227 permit movement of slab 225 relative to slab 223 and 221 in th same manner as the lower slab 23 is movable relative to sla 21 in embodiment 20; however, the reduction of length o column of each rod member as 228, 229 and 230 from top sla to bottom slab permits a lesser weight of steel than wher one column, as 26 uninterruptedly reaches from the top sla to the bottom slab of a segreσated slab structure. Th slabs 221, 223 and 225 are formed in the same manner as are slabs 21 and 27 in apparatus 20. Figure 16 shows a portion of a building structure 240 comprising a vertically elongated segregated slab structure 238 and a horizontally extending segregated slab structure 239. The slab 238 comprises vertically extending spaced apart slabs 251 and 252 and an interslab space 26. The structure 240 incorporates not only segregates slab struc¬ tures as in FIGS. 1 (at 238) an 17 (at 239) but also fluid carrying conduits 241 in the inner wall 251 and conduits 246-249 in the outer wall 252 for carrying' heating and/or cooling fluids. Those conduits are incorporated in the molds when the slabs as 251 and 252 are formed in same man¬ ner as slabs 21 and 23 are formed. The slabs 251 and 252 have the same structure as slabs 21 and 23 and the interslab space 260 is like interslab space 22 but the length and width of slabs 251 and 252 and interslab space 260 extend vertically. The rows of rod members as 271, 272, and 273 in the interslab space 260 are formed in an array 270 of rod mem¬ bers which array is structurally and functionally like the array 25 of rod members in embodiment 20. The relations of the slabs 251, and 252 and interslab space 260 and array of rod members 270 is the same as in embodiment 20 structurally and functionally. A fluid conduit 262 for the line 261 to the exterior series of fluid conduits 246-249 in wall or slab 252 passes via a directional or selection control valve 257 and a vol¬ ume control valve 258. A fluid inlet line 256 to the line 255 passing to the series of conduits 241-245 in wall or slab 251 also passes to those conduits by way of the direc¬ tion control valve 257 and a separate volume control valve 259. The conduits as 244-249 are located in the molds, as 51 and 52 for the slabs, as 251 and 252. The thermal expansion and contractions of the walls due to the tempera¬ ture of the fluid in the conduits does not cause localized strain on the web portions because the metal as array 270 are capable of displacement to an S-shape on expansion of one or the other of the walls as 251 and 252. The conduits as 246-249 in the outer wall or slab ser to pass liquid heated by a heat source, as by roof pan solar energy which water is not hot enough to provide ambient air temperature comfortable to humans in the inte ior room as 267 enclosed by the interior walls 251, but adequate to so affect the temperature differential betwee the inner and outer walls 251 and 252 and so reduce the he loss from the interior wall 251 and enclosed space 267 t the exterior wall and the outer space 268 adjacent the out wall. The conduits 241-245 in the inner wall are useful f passing cooled liquid, as from and evaporative air cond tioner, to the walls of the house adjacent a room for habi ation without development of undesirable amount of humidit Figure 17 shows an embodiment 280, wherein reinforce concrete slabs 291 and 293, each formed similarly to sla 21 and 23, are spaced apart by an interslab space 292 wher • in an array 294 of rod members is located; such rod member are steel reinforcing rods as in embodiment 20, and are ar rayed in rows so that all rod members as 281-290 are tha extend in one of several vertical planes such as 146, 147 o 148. The slabs 292 and 293 are each provided with matts reinforcing steel, 295 and 296 respectively like matts 6 and 64 in embodiment 20. The matts 295 and 296 are joine to the reinforcing bars by wire or by welding; and the matt 63 and 64 may be similarly joined to the reinforcing ro members of the array 25 in embodiment 20. The rod members 281-290, in the embodiment 280 shown i FIG. 17 are arrayed in non vertical orientation relation t the horizontally extending slabs 292 and 293. Such orienta tion of those rod members allows the spacer and suppor units as 58 to be passed between molds when such segregate « slab units as 292 and 293 as shown in FIG. 17 are formed Diagonal steel tension bearing members as 297 and 298 in th upper and lower slabs 291 and 293 may be used, together wit a compression member 299, to further increase the strengt of the composite structure 280. A composite segregated slab building unit 300 of FIG 21 comprises a segregated slab roof structure unit 301, a • left wall structure unit 302, a right wall structure unit 303 and a floor and foundation structure unit 304. It is shown in assembled condition and in exploded view in FIG. 21 to show the relations of its parts more clearly, with the assembled array in the center of the figure and the units 301, 302, 303 and 304 thereof circu ferentially there¬ of and spaced apart from the assembled view. The roof structure unit is formed of upper slab 308 like slab 21 of embodiment 20 and lower slab 309 like slab 23 spearated by interslab space 310, like interslab 22 with an array of rod members 311 (like array 25 in embodiment 20) in the interslab space and connectd to the slabs 308 and 309 in the same manner as array 25 is connected to slabs 21 and 23 in embodiment 20. The wall structure unit 302 is formed of an outer slab 312, and inner slab 313 and interslab space 315 (like slab 21, slab 23 and interslab space 22 respectively in embodi¬ ment 20) with the slabs connected by an array or rod members 314 like the array 25 in embodiment 20. The wall structure unit 303 is formed of an outer slab 316, and an inner slab 318, with an interslab space 317 (like slabs 21, 23 and interslab space 22 respectively in embodiment 20) with the slabs 316 and connected by an ar- ray of rod members 319 like the array 25 in embodiment 20. The base and foundation member 304 is composed of a floor unit 305 and two foundation members 306 and 307. The slabs 320, 321, 324 and 327 have the same structure as the slabs 21 and 23 of embodiment 20. The floor structure unit 305 is formed of upper slab 320 like slab 21 of embodiment 20 and lower slab 321 like slab 23 separated by interslab space 323 like interslab space 22 with an array of rod members 322 (like array 25 in embodiment 20) in the interslab space and connected to the slabs 320 and 321 in the same manner as array 25 is connect¬ ed to slabs 21 and 23 in embodiment 20. The foundation structure unit 307 is formed of an outer portion of lower slab 321 and lower slab 324 and interslab / : -- - - - 16 - space 326 (like slab 21, portion of slab 23 and intersla space 22 respectively in embodiment 20) with the slabs 32 and 321 connected by an array or rod members 325 like th array 25 in embodiment 20. The foundation structure unit 307 is formed of an oute portion of lower slab 321 and a lower slab 327 with a interslab space 328 (like slabs 21, a portion of slab 23 an interslab space 22 respectively in embodiment 20) with th slabs 327 and 321 connected by an array of rod members 32 like the array 25 in embodiment 20. The foundation structure unit 307 is formed of an oute portion of lower slab 321 and a lower slab 327 with a interslab space 328 (like slab 21, a portion of slab 23 an interslab space 22 respectively in embodiment 20) with th slabs 327 and 321 connected by an array of rod members 32 like the array 25 in embodiment 20. Unit 304 is a composite of embodiment unit 20 and th three-slab structure of embodime'nt 220 and the portions 30 and 308 separately like embodiment 20 but smaller than uni 305. The structure 304 is particularly stable against crack ing and is low in cost of construction and has the therma advantages above described. The segregated structure of FIGS. 1 and 7 show a step ped structure at the ends. Such steps provide that th weight of the segregated slab is supported at its top sla and bottom slab member 23 may move relative to the top sla member 21 in a direction parallel to the plane of the lengt and/or width or the top member and so relieve strain tha may otherwise be applied thereto when such stress is applie to the lower member as to change its dimensions or positio relative to the top member. This movement of the ' lower mem ber relative to the upper member is accomplished notwith standing the dimensional stability of the top slab and th support in a vertical direction provided by the bar member of array 25 to the upper member slab 21. Inasmuch as th steel bars as 26-29 are flexible transversely to thei length there is allowed a movement of lower slab relative t ^ TR the upper slab in an amount only limited by the flexibility of the steel bar members in the interslab space. In the case of vertically extending segregated slabs as shown in FIG. 16 is the inner wall may move vertically relative to the outer wall, and vice-versa, rather than the upper and lower walls referred to in describing the actions of the components of the segregated slab structure of FIG. 1 and like apparatuses as in FIGS. 12, 14 and 15 which extend for their length and width in horizontal planes. In a particular embodiment as shown in FIGS. 18-20, with an assembly as 20 in form of a slab 8 feet long and 8 feet in height, with concrete 5.375 in. thick in slab 21 and 3.675 inches thick in layer 23 and 8 inches interslab space 22 and 0.5 inch of plaster on bottom surface of layer 23, the U valve is .061 B.T.U./hr. loss. Also, with a segre¬ gated slab apparatus as in embodiment 20, and shown in FIGS. 18-20.with FIG. ' 18 in plan view and concrete shown as trans¬ parent to show location of bars of mass 63 and like 47 with¬ in the concrete mass such embodiment being thirty feet long, 24 inches in height from top plane of slab 21 to bottom sur¬ face of slab 23, with #6 bar mesh running horizontally in each slab and #8 bars extending between the slabs, and 2 feet distance between the planes of the rods made of #8 rod and the mesh 63 in 1 foot squares and 4 inches thickness of slab 21 and 2 inches for slab 23, provides a bearing strength of 195 lbs. per linear foot with 2 feet between bars as 26-29. The actuator mechanism 104 and 105 of the spacing units 58 and 59 may be hydraulically actuated, in¬ stead of mechanically as shown in FIGS. 3, 10 and 11.

Claims: - Claims 1. A structural precast structure assembly produc comprising a first rigid slab comprising concrete, a secon rigid slab comprising concrete and an array of steel ba members therebetween; said first and second slab spaced away from each other, the first slab extending between a first plane and a secon plane, said first and second planes parallel to each other, and the space between said first and second planes occupie by a rigid material, comprising concrete and steel, the second slab extending between a third plane and fourth plane and said third and fourth planes parallel t each other and spaced away from each other and the spac between said third and fourth planes occupied by a rigi material comprising concrete and reinforcing steel; said first and fourth planes spaced apart from eac other and parallel to each other, said second and thir planes located between said first and fourth planes, sai second plane located between said third and first planes, said third plane located between said second and fourth planes; said second and third planes spaced apart from eac other by an interslab space, rigid steel bar member extending from said material between said third and fourt ■ planes to the material between said first and second planes, each of said steel bar members having one part thereo located between said second and third planes and directl exposed to the interslab space, and another part of each o those steel bar members being firmly attached to the material between said first and second planes and another part of each of said steel bar members being firmly attache to the material between said third and fourth planes, the length of each of said steel bar members extending between said slabs located in an array of parallel flat planes, sai slabs connected to each other only by said steel bar members whereby the slabs are movable relative to each other i directions transverse to said planes and to the length o said steel ^ members to the limit of the flexibility of said steel bar members. 2. A structural precast structure assembly product as in claim 1 comprising a third rigid slab comprising concrete, and a second array of steel bar members therebetween; said second and third slabs spaced away from each other, the third slab extending between a fifth plane and a sixth plane, said fifth and sixth planes parallel to each other, and the space between said fifth and sixth planes occupied by a rigid material comprising concrete and steel; said fifth and sixth planes spaced apart from each other and parallel to each other, said fourth and fifth planes located between said third and sixth planes, said fifth plane located between said fourth and sixth planes, said fourth plane located between said thir and fifth planes; said fourth and fifth planes spaced apart from each ' other by an interslab space, rigid steel bar members extending from said material between said third and fourth planes to the material between said fifth and sixth planes, each of said rigid steel bar members having one part thereof located between said fourth and fifth planes and directly exposed to the interslab space, and another part of each of those steel bar members being firmly attached to the material between said third and fourh planes and another part of each of said steel bar members being firmly attached to the material between said fifth and sixth planes, the length of each of said steel bar members extending between said second and third slabs located in an array of parallel flat planes, said second and third slabs connected to each other by said steel bar members whereby the second and third slabs are movable relative to each other in directions transverse to said planes and to the length of said steel members to the limit of the flexibility of said steel bar members. 3. Apparatus as in claim 1 comprising a plurality of tension bearing means each located between said second an third planes and each firmly connected to two of said stee bars between said second and third planes. 4. Apparatus as in claim 3 wherein said tensio bearing means are rigid steel bars. 5. Process for forming an overall rigid composit segegated slab product comprising two yieldably spaced apar slabs of concrete comprising the steps of pouring a firs mass of concrete in the form of a first flat slab having width and length very much larger than its thickness, an then forming a floor above and spaced from the top of sai first slab while supporting rigid bars extending verticall from within said first mass to above said floor, pouring second concrete mass on said floor and attaching one end o each of said bars to one of said slabs and another end o each of said bars to the other of said slabs. 6. Process as in claim 5 for forming an overall rigid composite segregated slab product comprising three yieldabl spaced apart slabs of concrete comprising the steps of forming a second mass of concrete in the form of a secon flat slab having a width and length very much larger tha its thickness, and then forming a floor above and spaced from the top of said second slab while supporting rigid bars extending vertically from within said second mass to above said floor, pouring a third concrete mass on said floor and attaching one end of each of said bars to said third slab. 7. A slab mass support and spacing unit comprising a first, rigid, upper, casting surface and casting support unit, a second, lower, support and bearing surface unit, a set of expansion links, and an expansion link set actuating assembly, the upper casting surface and surface support unit comprises a rigid steel T-sectioned top plate having a smooth upwardly facing top surface with a rectanguar outline - _ and a top plate support flange, said plate and plate support flange firmly joined together as a rigid "T" shaped section with plate on top and support therebelow, the lower support and bearing surface unit comprising a rigid steel T-sectioried bottom plate having a smooth downwardly facing bottom surface and an upwardly extending guide flange firmly joined together, the set of links comprising a plurality of like expansion link sets, each of which joins the downwardly extending upper flange and the upwardly extending lower flange, each set of expansion links comprising an upper link, pivotally joined to the upper flange at an upper link pin firmly joined to the upper flange, and a lower link, pivotally joined to the lower flange at a lower link pin, and firmly attached to the lower flange, the lower end of the upper link and the upper end of the lower link pivotally joined at a center link pivot pin, the center link pivot pin of one set, and the center link pin, of another set of links joined by a rigid control link, one flange firmly connected to a first rigid control arm and the .other flange pivotally connected to a second control arm, whereby to provide for adjusting the upper casting surface and support unit relative to the lower support unit while parallel thereto. 8. A static structure comprising a roof composed of a segregated slab as in claim 1 wherein said first through fourth planes extend horizontally and a vertical wall comprising a vertically extending structure as in claim 1 wherein said first through fourth planes extend vertically. 9. A structure as described in claim 8 and also comprising a foundation structure comprising three segregated slabs as described in claim 3. •

Inventors: DENZER W
Applicants: DENZER W
Application year: 1981
Main classification: E04G11
IPC codes: B28B23, E04B1, E04C2