Patent Publication Number: US-7895960-B2

Title: Process for the production of a frame for construction and frame thus obtained

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims benefit of priority and incorporates by reference PCT/FR2005/051120 filed Dec. 20, 2005 and French Application 04/53141 filed Dec. 21, 2004. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     None. 
     THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
     None. 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     None. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a process for the production of a frame for construction, particularly for a frame more particularly adapted to a construction adapted to float, such as is described in Patent Application WO 03/31732. 
     2. Description of Related Art 
     Patent Application WO 03/31732 proposes a construction adapted to move between a first position bearing on the ground and a second position floating. According to this document, the frame of the construction is constituted of joists of galvanized steel or aluminum for example, forming a network adapted to receive the insulated flooring of a construction. This network is necessary to ensure the distribution of the load and to preserve the plan of the flooring. 
     The frame also comprises flotation means in the form of caissons trapped in the network of the metallic structure formed by the joists. 
     Even if this mode of construction provides a suitable basis for construction, it does not give complete satisfaction for the following reasons: 
     In the first place, the metallic structure must be treated to be able to resist corrosion, particularly if it is used as a frame for a construction as described in Patent Application WO 03/31732. This treatment necessarily leads to an increase of the cost of the structure. Moreover, given the use, this surface treatment has the tendency to deteriorate, rendering necessary periodic maintenance. 
     In the second place, the production by mechano-welding of the structure leads to a large number of production hours leading to a high cost of the structure. This price is the greater, the greater is the price of steel itself. 
     Moreover, the insertion of flotation means in the form of caissons within the metallic structure in the form of a network is relatively long and complicated to carry out, leading to an increase in the cost of the frame. 
     Finally, it is necessary to ensure a resistant mechanical connection between the flotation means and the metallic structure rendering even more complicated and hence more costly the process of production of such a structure. 
     Also, the present invention seeks to overcome the drawbacks of the prior art by providing a process for the production of a frame for a construction, particularly a frame for a construction adapted to float such as described in Patent Application WO 03/31732, said process being simple to use, permitting reducing the cost of production and obtaining a resistant structure from the mechanical point of view. 
     BRIEF SUMMARY OF THE INVENTION 
     To this end, the invention has for its object a process for the production of a frame floor a construction adapted to float, characterized in that it comprises the steps consisting in:
         forming flotation means whose upper portion comprises a network of grooves adapted to form a framework for concrete beams as well as wells, passing through said flotation means, adapted to form framework for concrete columns,   preferably, arranging pieces of iron in the framework and adding at the periphery of framework to form a belt, and   casting the concrete.       

     The present invention also provides a frame obtained according to the mentioned process as well as a module used to make up said frame. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Other characteristics and advantages will become apparent from the description which follows, of the invention, which description is given only by way of example, with respect to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a frame according to the invention, 
         FIG. 2A  is a cross section of the frame according to a first modified embodiment, 
         FIG. 2B  is a cross section of the frame according to another modification, 
         FIG. 3  is a perspective view of a module used to form a frame, 
         FIG. 4  is a top plan view of modules assembled to form a frame, 
         FIG. 5  is a top plan view of the module shown in 
         FIG. 3 , 
         FIG. 6  is a cross section of the line VI-VI of  FIG. 5 , 
         FIG. 7  is a cross sectional view showing two modules assembled according to a first plane in vertical cross section, 
         FIG. 8  is a view showing the assembled modules, 
         FIG. 9  is a view showing in detail the assembly means, 
         FIG. 10  is a top plan showing the modules surrounding the conduit provided with the frame to permit the passage of guide piling, 
         FIG. 11  is a side view showing in detail the half module provided for the passage of the piling provided with an insert forming a reinforcement, and 
         FIG. 12  is a perspective view showing the insert forming a reinforcement. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In  FIG. 1 , there is shown a frame  10  on which can be connected a construction (not shown). This frame  10  is more particularly adapted to move the constructions movable between two positions, a first bearing on the ground and a second floating, such as described in the Patent Application WO 03/31732. However, this frame can be used for other types of constructions requiring a frame forming a foundation outside the ground. 
     According to the invention, the frame comprises flotation means  12  whose upper portion comprises a network of grooves adapted to form framework for beams  14  of concrete, as well as wells, passing through said flotation means  12 , adapted to form formwork for the columns  16  of concrete. 
     This arrangement permits obtaining a resistant frame thanks to the network of beams  14 , adapted to receive a slab or a floor for construction, said frame being adapted to resist the compressive forces produced by the construction thanks to columns  16 . 
     As shown in  FIG. 1 , the network is constituted by a first series of beams preferably equidistant and a second series of beams, preferably equidistant, perpendicular to the first beams. 
     The cross section of the beams, the distance separating the beams as well as their number, are determined by one skilled in the art as a function particularly of the load adapted to be applied to the frame  10 . Similarly, the cross section of the columns, their number and their emplacement are determined by one skilled in the art such that the frame will resist compressive forces. 
     Preferably, the columns  16  are disposed at the level of the intersections of the beams  14 . 
     According to another characteristic of the invention, the beams  14  interconnect the columns  16 , and have a lower surface in the form of an arch, as shown in  FIGS. 2A and 2B , thereby to increase the mechanical properties of said beams  14 . 
     Preferably, the feet of the columns  16  comprise shock absorber means  20 , projecting from the lower surface of the flotation means  12 . According to one embodiment, the shock absorber means are obtained from a rubber insert  22  as shown in  FIG. 7 , disposed in the lower portion of the wells into which are poured the columns. Each insert  22  comprises an upper portion having a small collar adapted to bear against a shoulder provided in the lower portion of the wells. This arrangement permits increasing the resistance of the frame and of the construction in case of an earthquake, by separating the frame and the construction from the ground. This arrangement permits imparting to the frame anti-earthquake properties. 
     According to another characteristic of the invention, the frame  10  comprises at the level of its upper portion, at the periphery, a belt  24  of reinforced concrete adapted to form a constriction. According to a preferred embodiment, the frame comprises at its periphery a formwork  26  in the form of a U-shaped gutter of which a first branch  28  is connected to the flotation means  12 . Tension members  30  are preferably provided to connect the upper ends of the branches of the U-shaped gutter so as to avoid deformation of said gutter during pouring the concrete. The tension members  30  are distributed all about the belt. According to modified forms, the formwork  26  can be connected directly to the flotation means  12  and/or the tension members  30  can be connected by any suitable means, such as for example by welding, to the ironwork provided for the beams  14 . 
     According to a simplified modification of the invention, the process of production of a frame for construction comprises the following steps consisting in:
         forming the flotation means  12  whose upper portion comprises a network of grooves adapted to form framework for beams  14  of concrete, as well as wells, passing through said flotation means  12 , adapted to form formwork for the concrete columns  16 ,   preferably, arranging ironwork in the framework and adding at the periphery of framework to form a belt, and   pouring the concrete.       

     After the concrete sets up, the formwork used to cast the concrete forms the flotation means. Thanks to the network of beams connected to the wells, there is obtained a mechanical connection between the concrete portion and the flotation means. This connection can be reinforced by any means, such as for example by increasing the roughness of the surface of the flotation means forming a formwork. 
     According to a first modification, the frame  10  comprises only a network of beams in the upper portion as shown in  FIG. 1 . According to another modification, the frame  10  is covered with a concrete slab comprising in its lower portion the beams  14  of the columns  16 . 
     According to a preferred modification, the flotation means  12  are made by assembly of several modules  32  as shown in  FIGS. 2B ,  3 - 9 , said modules being made by molding plastic material. According to a simplified modification, the flotation means can be made of a single component as shown in  FIG. 2A . 
     According to one embodiment, the module  32  of substantially parallelpipedal form is made by rotomolding. 
     The height of the modules  32  is adjusted as a function of the load supported by the frame such that this latter can particularly float. As a modification, there can be stacked layers of modules  32  so as to increase the flotation capacities of the frame. To this end, the upper surface of the module has a shape adapted to coact with the lower surface of the upper module. 
     Each module  32  comprises at the level of its upper surface two grooves  34  and  36 , adapted to form a formwork for the beams  14 , said grooves  34  and  36  being preferably substantially perpendicular and in a median position when the module has a square or rectangular shape. 
     As a supplement, the module comprises a well  38  adapted to form a formwork for a column  16 . Preferably, the well  38  is disposed at the intersection of the grooves  34  and  36 . 
     Preferably, the bottom of the grooves  34  and  36  is incurved and inclined toward the well  38  so as to form arches when the modules are assembled, as shown in  FIG. 2B . 
     According to a modification, the process for production consists in assembling modules  32  so as to form flotation means  12  with an upper portion of a network of grooves adapted to form formworks for the concrete beams  14  as well as for the wells, passing through said flotation means  12 , adapted to form formwork for the columns  16  of concrete, as shown in  FIG. 4 . 
     When the modules are assembled, the concrete can then be cast, after having preferably added reinforcing iron in the formwork as well as if desired the formwork forming the peripheral belt. 
     As shown in  FIGS. 3 and 5 , the throats  34  and  36  define in the upper part of the module four sectors  40  each with projecting portions  42  adapted to coact with hollow shapes provided below the lower surface of an upper module. Preferably, for increased productivity, all the modules are identical no matter what the layer. Thus, a same module comprises an upper surface with projecting elements  42  and a lower surface with hollow shapes whose forms are adapted to those of the projecting elements  42 . 
     According to another characteristic, as shown in  FIG. 6 , each module comprises in its upper portion at least one recess  44 , preferably four at the level of each sector  40 . These recesses  44  increase the resistance to compression of the module. 
     Preferably, the lateral walls of the module also comprise recesses  45  also permitting reinforcing the resistance to compression of the module. 
     According to another characteristic of the invention, the frame comprises assembly means  46  permitting connecting the different modules  32  preliminarily to the casting of the concrete and during hardening. These assembly means  46  comprises a rod  48  with at each end a hook  50 . The length of the rod is such that a first hook  50 . 1  will be disposed below the modules and a second hook  50 . 2  will be disposed above the modules, as shown in  FIG. 8 . As a supplement, at least one nut is provided to coact with a screw thread provided on the rods so as to press the hooks  50  against the modules and to lock said modules so as to hold them assembled before casting the concrete. Preferably, as shown in  FIGS. 8 and 9 , the hooks  50  have curved ends  52  adapted if desired to coact with hollow shapes provided at the level of the modules so as better to grip said modules. 
     According to modifications, when the frame comprises several layers of modules, the rods  48  extend over all the height of the frame or connection means  53  are provided to connect the rods of the different levels, as shown in  FIG. 9 . 
     Preferably, the rods  48  are disposed at the level of the region of connection of four adjacent modules. To this end, the modules comprise at the level of each angle, a quarter circle cutout  54  extending over all the height of the sidewalls, as shown in  FIG. 5 . When four modules are assembled, the four adjacent quarter round cutouts  54  form a conduit  56  adapted to receive a rod  48 , as shown in  FIG. 4 . According to another embodiment, in addition to the quarter round cutouts  54 , each module comprises at the level of each sidewall, two half round cutouts  58  offset relative to the summit, extending over all the height of the lateral walls, as shown in  FIG. 4 . When two modules are assembled, the half round cutouts  58  form a conduit adapted to receive a rod  48 . These cutouts  58  facilitate assembly of the modules disposed at the periphery. 
     The process for production of a frame is easy and greatly simplified. It suffices to assemble a suitable number of modules  32  as a function of the surface and the desired shapes of the frame. To hold them assembled, the rods  48  and the hooks  50  are emplaced. If necessary, a second layer or even several layers of modules are thus assembled. 
     Thus, as before, there is obtained at the level of the upper layer a network of grooves adapted to form formwork for concrete beams  14  as well as wells, passing through said flotation means  12 , adapted to form formwork for the concrete columns  16 , as shown in  FIG. 4 . The modules being all identical and being disposed on each other, the wells of each layer coact, permitting obtaining frameworks for columns  16  extending over all the height of the frame. 
     When the modules are assembled, the concrete can then be poured, after having preferably added reinforcing iron into the formwork as well as if desired the formwork forming the peripheral belt. 
     According to the process of the invention, there is obtained in an economical manner a frame adapted to support a construction. 
     Thus, the modules can be made in an industrial manner, which leads to lowering the cost of production. These modules can be then assembled in situ in a rapid manner. Different sizes and shapes of forms can be obtained by assembling identical modules according to the invention. As a function of the load to be supported, the characteristics of the frame can be increased by assembling one or several layers of modules. 
     Thereafter, it suffices to pour the concrete. After hardening, the frame is directly obtained. 
     As indicated above, the frame obtained by the invention permits obtaining a floating frame adapted to support a construction so as to obtain a floating construction. However, the present frame could be used in other applications, particularly when it is desired to obtain a foundation out of the ground, disconnected from the ground, such as for example for an earthquake proof construction. 
     Preferably, the frame is adapted for construction as described in the Patent Application WO 03/31732. 
     In this case, the frame comprises at least one conduit passing through the frame along its height, to permit the passage of a pile along which the frame can slide when the water level rises and the frame  12  floats. 
     Preferably, the frame comprises several conduits  62  adapted to receive piles along which the frame  12  can slide. 
     According to one embodiment, each conduit  62  is provided in a module  64 . Preferably, this module  64  comprises reinforcing means  67 , preferably metallic, delimiting the conduit  62 , adapted to reinforce the module and to limit the deformation of said conduit  62 . Preferably, the reinforcing means  66  are connected to the network of beams  14 . Thus, they can be embedded at least in part in the network concrete beams or connected to the reinforcing iron used for the network of beams  14 . 
     According to a preferred embodiment and illustrated in  FIG. 10 , the module or modules  64  are each obtained from two half modules  64 . 1  and  64 . 2  that are symmetrical about a vertical median plane  68 . In this case, the reinforcing means  66  are in two parts, one part for each half module  64 . 1  and  64 . 2 . According to one embodiment, the half modules are made by molding, the reinforcing means  66  forming inserts integrated into the mold and partially embedded in the molded material. 
     The reinforcing means  66  comprise for each half module a cradle  70  with a cross section in a vertical plane of U shape, said cradle  70  being obtained by the assembly and welding of profiles. Thus, each cradle comprises two U shapes, one disposed at the level of the upper plane of the module and the other disposed at the level of the lower plane of the module, crosspieces connecting the U&#39;s at the level at the ends of the arms of the U and on opposite sides of the base of the U, as shown in  FIGS. 11 and 12 . 
     When the half modules are disposed one against the other, cradles  70  are disposed facing and form a conduit  62  as shown in  FIG. 10 . 
     To improve the mechanical characteristic, the reinforcing means  66  comprise for each half module a U-shaped cradle and legs  72  and the half modules comprise throats  74  in prolongation of the throats of the adjacent modules, said legs being disposed at the level of said throats  74 . This arrangement permits connecting the reinforcing means  66  to the network of beams  14 . According to one embodiment, preferred and shown in  FIGS. 10 and 12 , a first leg  72  is provided extending perpendicularly to the base of the U of the cradle  70  in a substantially vertical plane, the other legs  72  extending perpendicularly to the branches of the U from their ends in a vertical plane. 
     As before, the half modules are preferably made by rotomolding. 
     They are assembled in situ to the other modules  32 , thanks to the assembly means  46 . Once assembled, the modules form flotation means  12  with, at the level of the upper surface, a network of throats adapted to form formwork for the concrete beams  14  as well as the wells, passing through said flotation means  12 , adapted to form formwork for the concrete columns  16 . 
     When the modules are assembled, the concrete can then be poured, after having preferably added reinforcing iron in the formwork as well as if desired the formwork forming the peripheral belt. 
     According to this embodiment, a portion of the legs  72  is embedded in the network of beams  14 , which contributes to the improvement of the mechanical properties of the obtained frame. 
     Of course, the invention is clearly not limited to the embodiment shown and described above, but on the contrary covers all the modifications particularly as to the dimensions and the materials of the different elements forming the frame. Finally, other materials could be used in the place of concrete to be cast in the grooves and the wells and to ensure mechanical resistance of the frame.