Abstract:
A method for off-site manufacture of prefabricated monolithic fireplaces etc comprising a plurality of concrete blocks ; the method comprising the steps of constructing a first layer of blocks, providing a steel frame and securing the same to the blocks and to a second layer of blocks constructed atop the first layer, and constructing additional layers of blocks sequentially atop the second layer each block being adhesively secured to each of its adjacent blocks.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Outdoor fireplaces, grill units, bars and even complete outdoor kitchens have been constructed on-site from concrete blocks and the like for some time and have been generally satisfactory. The cost of on-site construction, however, is substantial and quality control may be difficult to monitor and maintain in on-site construction resulting in a lack of structural integrity of the units and even in structural failure over time. 
         [0002]    It is the general object of the present invention to provide a prefabricated monolithic structure of high structural integrity for use in the efficient construction of outdoor fireplaces and the like, and an off-site method of making the same. 
         [0003]    It is a further object of the invention to provide a structure of the type mentioned which includes an integral high strength metallic frame resulting in a high degree of structural integrity of the overall structure, and which in turn facilitates the efficient transportation and on-site installation of the structure. 
         [0004]    A still further object of the invention resides in the provision of lifting devices particularly well adapted to lift, transport and install the aforesaid structure. 
       SUMMARY OF THE INVENTION 
       [0005]    In fulfillment of the aforesaid objects and in accordance with the present invention, an off-site prefabricated structure of concrete blocks or the like is provided with a first or base layer or course of blocks outlining the perimeter configuration of the structure. A rust proof frame of high strength metallic construction is provided with a configuration substantially the same as the base layer of blocks and is fixedly secured to the base layer of blocks in supporting relationship therewith to maintain their relative positions with respect to each other. A plurality of additional layers or courses of blocks are then provided atop the base layer of blocks and each block is affixed to each of its adjacent blocks by an adhesive bonding material. 
         [0006]    In a presently preferred form, the blocks of the first layer are somewhat wider than those of the second layer to provide a narrow substantially horizontal inwardly extending shelf defined by the top surfaces of the first layer of blocks inwardly around the perimeter of the structure. The structural frame is generally L shaped in cross sectional configuration with one leg arranged horizontally and engaging and affixed to the top surface of the base layer of blocks and with an integral vertical leg engaging and affixed to the inner surfaces of the second layer of blocks. Preferably, the structural frame is both bolted to and secured adhesively to substantially all of the blocks in both the first and second layers of blocks. 
         [0007]    While other high strength materials may be employed, the metallic frame is preferably constructed of structural strength steel with a rust proof coating. Various adhesives may also be used with a high strength masonry water-based bonding agent presently preferred. 
         [0008]    In the preferred practice of the method of the present invention, conventional off-site facilities conducive to efficient quality control and efficient low cost production are provided. A first layer of blocks is provided in a desired perimeter configuration and adhesively affixed followed by a second narrow layer of blocks, which defines the shelf for receiving the frame. The frame is then affixed in secure engagement with both the first and second layers of blocks both adhesively and with suitable bolts. 
         [0009]    Additional layers of blocks are then provided atop the second layer of blocks with each block in each layer throughout adhesively secured to each of its adjacent blocks. 
         [0010]    On completion of one or more structures required for a particular outdoor unit, the structures are transported for on-site installation on large trucks and lifting devices of the present invention, to be described hereinbelow, may be employed for loading and unloading the trucks and for locating the structures in their desired on-site positions. A fireplace, for example may require two structures one atop the other. Other units may require two or more structures assembled in various side-by-side arrangements etc. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  of the drawings is a perspective view showing an outdoor fireplace comprising two (2) prefabricated structures of the present invention one atop the other, 
           [0012]      FIG. 2  is a perspective view showing a fireplace similar to the  FIG. 1  fireplace but with wood storage box units on each side thereof, 
           [0013]      FIG. 3  is a grill unit including storage compartments and a sink and employing two (2) prefabricated structures of the invention in side-by-side relationship, 
           [0014]      FIG. 4 . is a bar unit comprising two (2) structures of the present invention in side-by-side relationship, 
           [0015]      FIG. 5  is a perspective view of a lower fireplace with the front portion thereof broken away, 
           [0016]      FIG. 6  is a plan view of a prefabricated structure of the present invention showing a metallic frame member forming a part thereof, 
           [0017]      FIG. 7  is an enlarged fragmentary sectional view taken as indicated at  7 , 7  in  FIG. 6  and showing a portion of the frame member, 
           [0018]      FIG. 8  is a schematic side view of a prefabricated structure of the present invention being transported by a conventional forklift truck with the forks entered in parallel openings at the base of the structure, 
           [0019]      FIG. 9  is a side view similar to  FIG. 8  but showing the prefabricated structure lifted by an overhead lifting device with depending lifting members engaging the structure, 
           [0020]      FIG. 10  is a schematic perspective view of the overhead lifting device, 
           [0021]      FIG. 11  is a plan view of a prefabricated structure provided with lifting connections for an overhead lifting device, and 
           [0022]      FIG. 12  is a fragmentary sectional view showing the overhead lifting device with a depending member connected with the frame of the structure. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    Referring particularly to  FIG. 1  of the drawings, an outdoor fireplace is indicated generally at  10  with a lower unit  12  and an upper unit  14 , the lower unit  12  having a conventional front opening  16  and the upper unit  14  having a cap  18  and a vertical through opening internally and serving as a chimney for the lower unit which is open at the top. The fireplace is constructed of concrete blocks with exposed aesthetic surfaces and a decorative emblem  20  may be included on the face of the upper chimney unit  14 . 
         [0024]    In  FIG. 2  the  FIG. 1  fireplace is shown in association with left and right hand wood storage units  22 ,  22 . The wood storage units  22 ,  22  are of similar construction with aesthetically pleasing concrete blocks and each is provided with a front opening  24  readily accessible for the storage of wood to be used in the fireplace. 
         [0025]      FIG. 3  illustrates a somewhat larger unit  26  which may comprise similar units  28 ,  28  in side-by-side adjacent relationship with a unitary top  30  mounted on the units  28 ,  28 . A sink may be provide as at  32 , with an adjacent storage compartment  34  and a covered grill unit  36  with further storage units  38  accessible through the front wall of the unit. 
         [0026]      FIG. 4  shows a bar unit indicated generally at  40  with storage compartments  42 ,  44  accessible in a top counter member  46  and front storage units accessible through doors  48  and  50 . The unit  40  may conveniently be constructed of a pair of similar units  52 ,  52  disposed in side-by-side relationship with the counter  46  disposed atop both units. 
         [0027]    In  FIG. 5  a lower fireplace unit  12   a  is shown with a portion of its front wall broken away at  54  to expose a portion of a metallic frame  56  better illustrated in  FIGS. 6 and 7 . The metallic frame  56  takes a rectangular configuration as best illustrated in  FIG. 6  and is disposed atop a first layer or course of blocks  58 ,  58 . In accordance with the method of the invention the blocks  58 ,  58  are arranged in the desired configuration for the perimeter of a structural unit in the course of the prefabrication of the unit. They may then be adhesively secured together with a pair of parallel openings  60 ,  60  in the front wall thereof and a similar pair of aligned openings  62 , 62  in the rear wall thereof. The openings  60 ,  60  and  62 ,  62  cooperate with a lifting device to be described more fully hereinbelow. 
         [0028]    The frame  56  is of a high-strength rust-proof metallic construction such as structural steel and preferably takes an L shape configuration in cross-section as best illustrated in  FIG. 7  with a horizontal portion  64  and an integral vertical portion  66 . The horizontal portion  64  is secured to the shelf portions of blocks  58 ,  58  of the first layer or course of blocks preferably by an adhesive  68  and bolts  70 ,  70 . Similar bolts  72 ,  72  secure the structural member  56  to the blocks  74  of a second layer or course of blocks disposed atop the blocks  58 ,  58  and somewhat narrower so as to provide the horizontal shelf for mounting the structural member  56  atop the blocks  58 ,  58 . The vertical portion  66  of the structural member is secured to each of the blocks  74 ,  74  by bolts  72 ,  72  and by adhesive  68 . Thus, the frame and the blocks of the first and second layers provide a base structure of high integrity for the structural unit  12   a . The metallic structural member  56  may also include a pair of U-shaped brackets  76 ,  76 , one shown in  FIG. 7 , disposed in the aforementioned openings  60 ,  60 . Similar brackets  76 ,  76  may also be provided in the openings  62 ,  62 . 
         [0029]    In accordance with the method of the invention, a plurality of blocks  78 ,  78  arranged in vertically stacked relationship may be assembled in a desired number of layers or courses atop the second layer of blocks  74 ,  74  with each block adhesively secured to all adjacent blocks to provide a monolithic structure of high structural integrity. 
         [0030]    A first method of transport for the prefabricated structures involves the aforesaid openings  62 ,  62  and brackets  76 ,  76  and a conventional fork lift truck. As will be seen in  FIG. 8 , a fork lift truck  80  can readily be employed with its forks entered in the openings and brackets and in engagement with the structural metallic member  56  to lift, transport and deposit a prefabricated structural unit onto a truck for long distance transport and then from the truck to its final destination. 
         [0031]    Secondly, and when the first method of transport is impractical or impossible to achieve, transport may be accomplished as illustrated in  FIGS. 9, 10, 11 and 12 . An overhead lifting device indicated generally at  82  can be provided for use with a fork lift truck  80 . The device  82  comprises a main frame member  84  and at least one depending lifting element  86 , four (4) preferred. The lifting elements cooperate with the structural frame  56  of a prefabricated structural unit and are manipulated by the frame member  82  and the fork lift truck  80  to lift and transport the prefabricated unit as necessary. As best illustrated in  FIGS. 9, 11 and 12 , the depending lifting elements  86 , 86  are connected at lower end portions with frame  56  as by threading the elements in the form of threaded rods into nuts  88 , 88  welded to the frame  56 . At their upper end portions the rods  86 , 86  are lifted or lowered as required by the frame member  82  and the fork lift truck  80 . Brackets  90 , 90  may be provided in two different right angularly related directions for this purpose. 
         [0032]    Finally, it should be noted that the second method of transport has the advantage of ease in effecting a slight horizontal adjustment during final positioning of a structural unit. When the depending unit is held slightly above its final position by a fork lift, manual force can be applied laterally by attending workmen in a slight swinging movement for horizontally positioning within a matter of inches. 
         [0033]    From the foregoing it will be apparent that a method has been provided for prefabricating a concrete block unit of high structural integrity at economic advantage. Highly effective methods of transport have also been provided.