U.S. patent application number 09/741787 was filed with the patent office on 2002-06-27 for methods of manufacturing and constructing a habitable, cementitious structure.
Invention is credited to Hunt, Christopher M..
Application Number | 20020078659 09/741787 |
Document ID | / |
Family ID | 24982193 |
Filed Date | 2002-06-27 |
United States Patent
Application |
20020078659 |
Kind Code |
A1 |
Hunt, Christopher M. |
June 27, 2002 |
Methods of manufacturing and constructing a habitable, cementitious
structure
Abstract
Invention is a synergistic whole comprised of processes,
machines, articles of manufacture and compositions of matter
required to construct a habitable structure comprised of a
cementitious product, in this example autoclaved aerated concrete
("AAC"), formed in unique blocks, panels and beams, resulting in an
extremely environmentally friendly habitable dwelling, residential
or commercial, which, due to the resultant synergy of embodiments,
when compared to a similar structure employing prior art and/or
current industry's standard materials and methods of construction,
is structurally superior and simultaneously yields substantial
savings in labor, time and costs.
Inventors: |
Hunt, Christopher M.;
(Atlanta, GA) |
Correspondence
Address: |
William B. Noll
402 Anemone Street
Panama City Beach
FL
32413
US
|
Family ID: |
24982193 |
Appl. No.: |
09/741787 |
Filed: |
December 21, 2000 |
Current U.S.
Class: |
52/745.13 ;
52/270; 52/285.1; 52/285.2 |
Current CPC
Class: |
F16B 15/06 20130101;
E04B 7/02 20130101; E04B 7/20 20130101; F16B 25/00 20130101; E04F
2019/044 20130101; E04D 13/0645 20130101; E04B 1/74 20130101; E04B
5/04 20130101; Y02E 10/44 20130101; Y02B 10/20 20130101; Y02E 10/40
20130101; E04F 13/08 20130101; E04B 1/04 20130101; E04F 19/0436
20130101; E04F 19/00 20130101; F24S 20/66 20180501; H02G 3/38
20130101 |
Class at
Publication: |
52/745.13 ;
52/285.1; 52/285.2; 52/270 |
International
Class: |
E04B 001/00; E04G
021/00; E04G 023/00 |
Claims
1. In a method of constructing multi-sided, habitable dwellings
principally from pre-cut sections of a cementitious material for
building up from a foundation, said method comprising the following
steps to form a wall: a.) selecting a discontinuous first course of
blocks for cementing on said foundation, where said first course
blocks include at least a longitudinal slot, with said slots of
adjacent blocks aligned; b.) said first course is having vertically
oriented blocks of predetermined size with length of "X" so that
top of said block closely equals height of door opening so that a
horizontal plane is formed along top of wall section; and c.)
adding horizontally aligned beams on top of said primary course,
where a planar top surface is provided, and d.) where openings in
said wall are located a on at least a 1' center course and a
predetermined structural component which is architecturally
finished on three sides borders said opening.
2. The method according to claim 1, wherein said aligned
longitudinal slots are aligned to define an internal continuous
slot for receiving utilities including the further step of
concealing the longitudinal slot by covering with subsequent course
of block.
3. The method according to claim 1, including the step of inserting
an arcuate configured insert into a receptive longitudinal slot at
any angled junction whereby to facilitate feeding of said utility
wiring through said receptive slots.
4. The method according to claim 2, including the step of providing
openings in communication with said continuous slot to house
utility electrical wiring outlets for access to said first living
level.
5. The method according to claim 1, wherein plural curved
cementitious blocks are utilized in said construction, and said
curved blocks are fabricated into predetermined curve shape prior
to cementitious material being in final cured state.
6. The method according to claim 1, including the step of using
manufacturing blocks with plural internal voids which when stacked
vertically align to continuously communicate from the base through
the upper most block so that the desired temperature communicated
in voids is able to effect block's material and offset negative
effects of exterior temperature.
7. The method according to claim 1, wherein said final course of
cementitious beams has an enclosed longitudinal void which can
house air duct system so that when said beams are joined a
resultant continuous duct system is developed, and openings are
made through said beam material into said air duct system as
required for living space.
8. The method according to claim 1, when completed said wall is to
support a roof system, wherein an uppermost course of blocks
includes a top angled planar surface to define a roof pitch for
securing a roof system thereto so that there is no gap between
angled roof system and top of said uppermost course of blocks and
the interior face may be architecturally modified for finished
appearance.
9. The method according to claim 1, including the step of
overlaying and spanning said final course of beams with
predetermined floor panels which have a slot manufactured into said
panel, with said slots of adjacent panels aligned, whereby placing
rebar and mortar into slot in effect slot becomes a bond/ring beam
which is integrated into said floor panel, and a.) at least an
upper level of embedded steel reinforcing stops shorter of panel
end which rests on said wall than any other embedded reinforcing so
that slot can be manufactured without interference from said
embedded reinforcing, c.) said panel end being allowed to be flush
with exterior wall face and still meet construction requirement of
bond/ring beam.
10. The method according to claim 8, including adding a stair
system to join said multiple living levels, where said stair system
is comprised of steps of predetermined cementitious material which
require no fasteners nor mortar, and a.) which said steps have a
slot manufactured into at least one end, which slot corresponds to
desired angle of stair's run, with said slots of adjacent steps
aligned, and b.) wall also has a corresponding said slot so that
when a guide mechanism which length runs from near lower living
level to short of upper floor level is inserted into wall slot, and
c.) as individual steps are placed into gap between upper end of
said guide and upper living level and said slot on step is
positioned onto said guide mechanism, the step is then lowered to
rest on floor and as process progresses the previous step until a
stair system connecting levels results.
11. The method according to claim 9, including the steps of
securing a prefabricated, predetermined elongated shapes similarly
shaped to a beam of cementitious product which may be reinforced
with steel and which can contain a continuous internal void
extending from end to end and is open at each end, said beam to
secured to said angled planar surface of cementitious material by
notching at least one part of either said beam and planar surface
so that scarfed joint engage and said beam and planar surface are
permanently fastened using only mortar and a metal helical
device.
12. The method according to claim 11, wherein said beam system
includes plural said beam members which connect to each other so
that a structural support system results from following steps: a.)
said beams have corresponding notched ends which match for close to
flush fit, and b.) said beams have a longitudinal cavity into which
reinforcing and cement can be inserted, and c.) said longitudinal
cavity aligns with other beam's said cavity so that reinforcing and
cement inserted flows through individual beams and thereby make one
monolithic system.
13. The method according to claim 12, wherein said beam system is
comprised of a.) have ends to flush fit, and b.) a predetermined
structural material, and c.) a permanently attached parallel
section of a softer cementitious material for receiving
fasteners.
14. The method according to claim 13, including the further step of
applying plural panels to said beam system, said method comprising
the steps of: a.) using fasteners which requires no pre-drilling
yet to allow adhesive to be inserted into cavity formed by said
fastening device, and b.) said plural panels which are installed at
an angle are held in desired position by fastening device while
adhesive sets.
15. The method according to claim 14, including the further step of
applying cementitious roof panels comprised of exposed vertical
face having a chamfer with at least one sharply reversing and
upward angled groove which aligns with other said panels running
parallel to the length of said roof face, said cementitious roof
panels having reinforcing design modified so that at least one
section of reinforcing stops shorter of panel end and/or side than
other sections, which resultant area void of reinforcing allows
panel to be modified by cutting a trough without interference.
16. The method according to claim 14, including the further step of
top surface face of said roof panels containing an engraved trough
running at a downward angle and with said trough of adjacent said
roof panels aligned so that moisture flows by force of gravity
through said trough.
17. The method according to claim 15, including the further step of
overlaying said roof panels with a polyester/nylon mesh fabric
featuring alternating sections of a tight mesh and a loose
mesh.
18. The method according to claim 16, including the step of
applying an elastomeric material to said mesh fabric, where said
elastomeric material penetrates only said loose sections to bond to
said roof panels, such that an air cavity is created between said
tight mesh and said roof panels, which predetermined said air
channel is of sufficiency for vapor permeability of roof panel and
runs unobstructed from lower starting position to near upper roof
ridge where it exhausts.
19. The method according to claim 15, including the step of
applying a roofing material on habitable dwelling which is:
waterproof, climate durable, chemical resistant, vapor permeable,
high modulus of elasticity, durable, tintable for various colors,
bonds well to cementitious material and can be continuously
re-coated so material never requires removal.
20. A dual operational fastening device for securing together
cementitious materials, said fastening device comprising: a.) shank
member having an annular wall, a core with opening at first end for
receiving material into which said fastening device is inserted,
and between said first core and an adjacent wall portion a second
core extending to an opening in second end into which an adhesive
can be inserted, plural annular cut-out portions extending
tangentially from said annular wall connecting to first said core,
and plural longitudinal recesses in said annular wall connecting to
said second core, and a helical thread arrangement about said
annular wall; and, b.) a broadened head member at first end of said
shank member, where said head member includes means for removably
securing a rotating hand tool and a void where thread becomes head
and end of head does not connect to thread, said opening enabling
fastener to counter sink.
21. A fastening device according to claim 19, wherein there are
plural sections of angled tangentical helical thread sections
protruding from a shank, to form said helical thread arrangement,
so that said thread sections assist the shank staying centered in
hole and on course during insertion so that adhesive can flow
around said thread sections and fill cavity between said shank and
wall of material.
22. The fastening device according to claim 21, wherein said
helical thread sections comprise: a.) thread sections wider at
shank and narrowing toward outer end, and simultaneously thread
sections are thicker at said shank and thinning toward the outer
end, and, b.) said sections are thinner at front leading edge and
thicker at second following edge and front leading edge from said
shank is shorter than back following edge.
23. A fastening device wherein fastening device is comprised of:
a.) voluted solid or hollow shank extending into plural helical
threads with very low number of revolutions around shank as it runs
distance of shank from pointed first end head to broad second end,
and b.) first end with point which can be exploded from within by
an item inserted into hollow shank from second broad end, and c)
said threads near first pointed end having openings in said thread
so that material is caught in it and assists device's grip in
material, and d.) said second end having a broad head which can be
hammered as means for removably securing said fastening device and
said head also containing a slot for receiving the bit of a
conventional screw driver for removing said fastening device, and
e.) said head on base houses prongs which crush cementitious
material performing a countersink effect for said head while being
inserted.
24. The method according to claim 2, including the step of
manufacturing curved blocks by a rounded mold inserted into current
art pan, which rounded mold has predetermined arch and size
compatible with desired product and cooperates with prior art pan
mold through current industry manufacturing process.
25. The method according to claim 2, including the step of
manufacturing curved blocks while cementitious material is in
"green stage" (still soft) a computer controlled mechanism with
cutting wires directs said wires through said "green" cementitious
material in a pattern which equates highest yield and least waste,
which results in curved cementitious blocks prepared for
curing.
26. The method according to claim 7 of manufacturing elongated
voids in a material by inserting a conical shaped implement in such
a manner that smaller end is imbedded in material and larger end is
at exterior of material so that implement can be easily removed
with minimal resistance, and a.) two said conical pieces can be
connected at smaller ends by having threaded male and female ends,
and b.) said conical insert can have an extending helical design so
that when removed ridged indentations are in cementitious material
to assist bonding when said elongated void is to be filled.
27. Method according to claim 20 which joins and simultaneously
reinforces two pieces of materials in one step by adding liquid
form of said material to said elongated cavity so when said liquid
flows out of said openings in annular wall and bonds to material
and sets it makes one monolithic, structurally reinforced piece
from plural pieces of materials.
28. Method according to claim 1 by which a fire rated wall can have
a door built of same cementitious material as wall.
29. Method according to claim 1 by which invented machines modify
plumb surfaces of cementitious material by creating openings and
architectural finishes using a template and guide system able to be
employed on permanently positioned vertical pieces.
30. Method according to claim 1 using a cutting system on a
vertical surface to create openings and architectural finishes by
steps of a) a male type rail system comprised of a bar attached to
the surface which is to be modified set a predetermined distance
from area to be modified, c) which said predetermined distance of
said rail corresponds to predetermined distance of a female,
receptive type brace on tool, so d) when said receptive brace is
guided along said rail an accurate work is completed.
31. Process according to claim 30 using predetermined blade
designed to cut varying depths, with duplicity of depths on each
end part allowing for a primary cut ledge edge to each side of
deeper cut to be manufactured, said matching ledges which will
receive a panel of industry thickness which spans and covers deeper
void housing items desired to be hidden within material and allows
it to be fastened with surface of said panel and receiving material
flush and so require no other furring.
32. Process according to claim 30 of a hand held machine capable of
modifying three surfaces simultaneously so that openings can have
two opposite faces and common joining face architecturally finished
in one step.
33. Process according to claim 21 wherein a hand held tool is able
to cut an elongated shaft of material out of a block using a single
blade, by a) blade being formed in a circular ring with at least
one planar side having teeth, and b) tool having driving and
stabilizing mechanisms which allow blade to be rotated and as
rotated cut out solid piece of material in which blade is imbedded
and encompasses.
34. Process according to claim 1 wherein a machine crushes and
pulverizes waste cementitious material into a preferred size and
said machine receives neutralizers and other desired ingredients so
end product is no longer a waste product but now used as a
nutritional enhancing soil conditioner.
35. Process according to claim 1 wherein a device in one motion is
able to remove excess material from face of a surface and smooth
out any residual material so that no other finish work is required,
device having, a.) front leading blade at such an angle as to
maximize ability to remove excess material and not gouge surface,
b.) handle at such an angle so that balances said blade and roller,
c.) roller being such that while it smoothes out residual material
it also serves as wheels which movement facilitates process, and
d.) an end following device which cleans off any residual material
which may accumulate on said roller.
36. Process according to claim 30 wherein precision guidance is
realized by a device which acts as a template for cutting utensil
by said guidance device being formed in predetermined shape equal
to formula: desired cut plus cutting mechanism equals size, device
being a.) a single unit with design emulating desired cut in open
or closed frame type, b.) device itself having protrusions which
penetrate into material being cut so that no other fastening
mechanism is required, c.) guidance device has structural ability
to withstand being driven into material.
37. Process according to claim 1 wherein a cutting tool has a blade
which is able to enter a material and cut it in desired direction
without any surface preparation, cutting device employing the use
of guidance plunge bars and coordinated with said guidance system
of claim 30, blade having, a) an elongate member of suitable saw
blade material having a width, length, thickness, a first leading
edge, a second trailing edge, a first end and a second end; said
first end being provided with means to connect to a reciprocating
mechanism; said first leading edge having saw teeth extending from
second end to a first position adjacent the means to connect to a
reciprocating mechanism, b) wherein said teeth are of uniform size
from first end until beginning of arc on leading edge near second
point, where teeth are of closer proximity along arc of first
leading edge, which arc terminates at middlest point of blade
width, which point is convergence of leading edge and second end
and trailing edge; and from second end trailing edge arcs away
towards first end with teeth of closer proximity but teeth are
positioned to be of neutral cutting angle having points
perpendicular to direction of blade length until arc ceases into
straight line of trailing edge which continues to first end; so
that blade resembles a sword with teeth along leading edge and
teeth only on first section of second point on following edge of
point.
38. Process according to claim 1 wherein a device inserts and
fastens wiring into a slot which has a narrow opening near floor
level and then rises up into a material so that slot is hidden from
view whereby tool has, a.) long handle with shorter curved piece
turned upward b.) at end of said upward curve a mechanism for
holding wire and simultaneously feeding it to desired location, c.)
fastening device for securing wire able to be directed from long
end of said handle.
39. Process according to claim 1 wherein an air duct system is
manufactured within a structural component of building and which
component when placed in position connects to other such components
so that result is a continuous interconnected duct system, and
openings for serving rooms are made by penetrating said structural
component and duct system, result being said system's air supply is
sufficient to service the building.
40. Process according to claim 1 wherein said walls are completely
constructed for a structure having a plurality of living levels and
only after walls are constructed are the floor and roof systems
installed by resting said floor system on a reinforced ledge which
is a structural component of wall system having an architecturally
finished face protruding from said wall and a.) the gap between
said floor system and said wall is converted into a bond beam by
rebar and cementitious material being placed into said gap and c.)
said gap is also converted to a utility chase by area not used as
bond beam having utilities placed therein and then finished floor
hiding utilities from view.
41. Process according to claim 40 wherein said walls are completely
constructed for a structure having a plurality of living levels and
only after walls are constructed are the floor and roof systems
installed by resting said floor system on a reinforced ledge which
is a steel plate inserted into wall system and creates said ledge
by protruding from said wall and a) said steel plate is welded at
joints to form a continuous reinforcing and thereby becomes a
structural bond beam as well as supporting ledge.
Description
BACKGROUND - FIELD OF THE INVENTION
[0001] This invention relates to processes, machines, articles of
manufacture and compositions of matter used to construct an
environmentally friendly habitable structure composed of a
cementitious material.
BACKGROUND OF THE INVENTION
[0002] The construction industry is basically unchanged in
materials and processes for hundreds of years, while during this
same time most other industries have been revolutionized. The
consequence is that there is vast room, and need, for improvement
in the construction industry, for the lack of improvement has
resulted in escalating costs and a compounding of negative impact
on the environment.
[0003] The construction industry has sought alternative building
materials and techniques in order to limit the traditional expenses
of construction. The costs include the high energy costs of
manufacturing, increasing scarcity of quality materials and the
rising cost of available materials, and increasingly expensive
construction labor. Regrettably, the majority of solutions employed
so far have only resulted in an increasingly inferior quality to
finished product. Consumers desire to lessen the negative
environmental impact (i.e.: deforestation, mining and pollution
from manufacturing) and negative health effects (i.e.:
fluorocarbons and other harmful gases, mold from decay) of some
building materials. These factors have forced home builders in
particular to consider new construction materials. These new
materials must be versatile, easy to use, durable, and energy
efficient.
[0004] There is an alternative, superior cementitious building
material available which satisfies these demands called Autoclaved
Aerated Concrete, hereinafter referred to as "AAC". AAC is superior
to current building materials and is extremely environmentally
friendly. While this invention applies to any cementitious material
which can employ the teachings of this invention, AAC will be
referenced.
[0005] AAC was invented in the early 1900's and consists of a
mixture of cement, aluminum powder, lime, water and finely ground
sand. This mixture expands dramatically, and this "foamed" concrete
is allowed to harden in a mold, followed by curing of the hardened
mixture in a pressurized steam chamber, or autoclave. Commercial
production of AAC began in the 1930's, and presently more than 31
million cubic meters have been produced worldwide.
[0006] Compared to wood, steel and standard concrete, AAC is a
clearly superior material as it is fire proof, termite proof, self
insulating, sound insulating, non decaying and does not rust.
Compared to concrete, AAC weighs 30% less than traditional concrete
masonry units. Additionally, AAC is well known as an
environmentally friendly construction material with certain
manufacturing plants receiving recognition as being "Green
Factories." Compared to the energy consumed in production of many
other basic building materials, only a fraction is required to
produce AAC. Raw materials consumption is very low for the amount
of finished product produced. In the manufacturing process, no
pollutants or toxic by-products are produced. AAC is also
completely recyclable.
[0007] AAC is an inorganic material that contains no toxic
substances. It does not slowly decompose nor emit a gas. Since AAC
is both a structural and insulation material it allows the
elimination of other materials that can contribute to poor indoor
air quality. Due to its inorganic structure, AAC also eliminates
the food source condition required to be present for microbial
growth to occur. Thus, AAC is resistant to water penetration and
decay. As it is a solid cementitious building material, insect
(roaches, ants) and rodent (rats, mice) infestation is impossible
within walls and floors as there are no cavities as now occurs in
standard frame construction.
[0008] Further, AAC is non-combustible, so in the case of fire it
can help prevent the fire from spreading to other rooms. During a
fire, no toxic gases or vapors are ever emitted from inorganic AAC.
As building methods using AAC include using solid blocks and panels
with very simple connection details, the ease of construction helps
to ensure a monolithic, highly fire-resistant wall.
[0009] AAC buildings can be very energy efficient. This efficiency
is due to a combination of high R-value, thermal mass and
air-tightness. AAC is the only product currently available that
meets Germany's stringent energy codes without added insulation. It
is well documented that the R-value of a mass product need not be
as high as that of light frame construction, to perform thermally
efficient. A recent study in the U.S. shows that an 8" AAC wall
performs much better than a conventional wood stud wall system with
an R-30 insulation.
[0010] AAC products are unfinished. Depending on the building use
or the aesthetic requirements, AAC may be coated with an exterior
surface finish of approved stucco, stone, brick-veneer, wood siding
with furring, or a combination thereof. On the interior AAC usually
has sheetrock installed over furring strips due to utilities and
numerous joints of blocks.
[0011] While the construction industry recognized certain
advantages in the use of AAC components for building, no system
exists to effectively take advantage of the superior qualities of
AAC in a cost effective manner. In fact, even though AAC is itself
considered a vastly superior construction material than current
construction industry standard wood, steel and/or concrete, the
prior methodologies employed in AAC construction cause ACC to be so
much more labor intensive and costlier than current standard
construction materials, that the negatives of prior methodologies
of AAC construction basically outweigh AAC's inherit advantages and
so prohibit AAC from being considered as a viable alternative. The
teachings of this invention not only eliminate these prohibitive
negatives, they so facilitate the construction of AAC habitats that
AAC habitats now can be built in less time and for less end use
cost than conventional materials, with the underlying theme being
the construction industry's prerequisite "simpler, better, cheaper"
motto. Current Methodology for AAC construction is exhaustively
represented in the Figures.
DESCRIPTION OF PRIOR ART
[0012] Despite the early development of AAC as a potential building
material, there is little in the patent prior art. There is a
recent patent, U.S. Pat. No. 5,286,427, Koumal, Feb. 15, 1994,
which relates to only a manufacturing process using a modified
composition for AAC. While it is helpful in finding a beneficial
use for what is now a waste product, it in no way addresses any of
previously mentioned problems prohibiting AAC's market acceptance.
So while it is helpful in finding a beneficial use for what is now
a waste product, it fails in that AAC still has no way of being
successful in construction industry, so it is dependent upon this
invention for its success.
[0013] The present invention is a synergistic whole, completed
structure as a precast concrete system and may appear similar to
U.S. Pat. No. 5,761,862 to Hendershot et al., Jun. 9, 1998, but
that is due only to also emulating a residential structure, as the
very nature of material used and processes employed are
incompatible. Of the searched Prior Art, it is the closest, yet
upon closer inspection it is vastly different in every respect.
Hendershot uses a very complex steel reinforcing and joint system,
bonding system requiring flared coil loops and sheebolts,
structural bearing system requires complex precast steel mechanism,
and a hip roof cannot be constructed as even simple dormers are
reduced to nothing more than exterior architectural accents placed
over constructed roof. All prior art requires great quantities of
steel reinforcing, steel brackets, mechanisms and/or laborious,
precise manufacturing processes facilitating site construction.
[0014] Wall process: U.S. Pat. No. 6,098,357 Franklin et. al., Aug.
8, 2000, cites well the problems of all prior art's various block
wall systems. Yet, itself requires additional materials for
architectural finish, its process of uniquely formed and
dimensional blocks greatly exceed the minimal three block vertical
height of current art, requires additional steel anchor system,
does not even address the problem of utility locations in walls and
it is composed of inferior material lacking all the innate
attributes of AAC. Referring again to U.S. Pat. No. 5,286,427,
Koumal, Feb. 15, 1994, fails in its design in FIG. 5 and
description to be so unfeasible that they are only intended as an
example of product and no way intended as representative of a
construction system. The present invention's processes and articles
of manufacture allow for the temperature transfer system which
heats/cools the wall for specific purpose of countering exterior
environment's temperature effects on wall material. Most prior art
is concerned with radiant heating of interior and not stabilizing
the insulate properties of wall's material, therefore their design
and processes are either inadequate or unfeasible.
[0015] In this invention's support beam system for roof, etc., the
prior art of U.S. Pat. No. 4,285,179, Goidinger, employs a
lightweight cementitious material in panel form that has
longitudinal cavities that are filled with heavy standard type
concrete and optionally reinforcing steel which makes vertical wall
panels load bearing. The roof beam system hereof with optional
reinforcing channel, is novel for following reasons: 1) Goidinger
is specifically vertical walls, 2) due to incompatible uses are
structurally and dimensionally dissimilar, 3) while Goidinger has
internal cavities formed by sandwiching formed wide panel halves
together, the solid rectangular beams hereof have much thicker
exterior AAC for distinct purpose of receiving "R" screws or
similar fasteners and can be shaped in angles to equal roof panel's
pitch, 4) beams can have corrugated shaped channel system adding
strength and additionally preventing added cement from adhering too
quickly to dry sides and clogging cavity and therefore preventing
it from being completely filled, which can be a serious failure
problem of Goidinger, and lastly 5) has a utility channel. It is
unobvious as no other prior art has specific use of: 1) weaker
material used for a structural purpose of receiving fasteners, 2)
used solely for structural, load bearing beams spanning space, as
without current art's "R" screws and interlocking beam ends it was
almost impossible to engineer such a system for practical
application. In regards to beam's interlocking ends, there is no
prior art in cementitious material, but U.S. Pat. No. 4,409,763,
Rydeem, Oct. 18, 1983 uses a great wood system of one vertically
oriented dowel to secure a plurality of intersecting beam ends onto
a post, but has no method for a suspended, self supporting, load
bearing beam system spanning space. Again, all other prior art in
cementitious materials employ complex, heavy duty steel brackets,
support/reinforcing, etc., and still cannot accomplish process of
invention.
[0016] In U.S. Pat. No. 5,794,386, to Klein, Aug. 18, 1998, there
is taught a roofing system. More specifically, the patent is
directed to a roof panel for sloped roofs and includes a
self-supporting reinforced plate of cementitious materials, wherein
the reinforcement above the plate has bars running along the slope
of the roof Compared to the present invention it is a very
complicated, costly combination of cement and steel
reinforcing.
[0017] Another aspect of this invention's roof system is its
gravity induced internalized gutter system. All prior art with
internalized gutter systems for precast concrete panels (Meyers,
U.S. Pat. No. 723,175; Novoa, U.S. Pat. No. 3,603,052; Rook, U.S.
Pat. No. 6,006,480) rely on force from additional moisture to push
accumulated previous moisture out of a level, straight gutter
system, and the results are problems of residual moisture and
accumulated debris causing damage to gutter system and structure.
U.S. Pat. No. 929,684, Mills & Taylor, Aug. 3, 1909, is an
example of common design deficiency allowing moisture to run down
the face so that debris residue leaves streaks and moisture can
drip back onto habitat if not incorporating invention's reverse
angle water deflection system.
[0018] No prior art addresses either processes or compositions of
matter of this invention's roof's water proofing system. Only U.S.
Pat. No. 5,981,030 Haupt et al, Nov. 9, 1999 has a figure similar
in appearance, but by closer inspection thereof, and by reading the
detailed description, the following incompatibilities, physical
differences and new unrelated processes become clear: 1) is not
used for waterproofing but rather water retention which defeats
process of facilitating removal of vapor from AAC roof panels, 2)
its process is a solid mass for water retention and not air
cavities for venting, 3) the materials used are completely
different and incompatible, 4) while absorber (4) is held in place
by fleece (1) and joined to base material (5) by a laminate (2),
there is no continuity as absorption is confined to small areas
(6), the laminate does not coat entire product but on specific
areas (6), the fleece has no structural purpose other than to hold
absorber (4), 4) quilted absorber areas are of various sizes and
perforated coating film contradict teaching of this invention.
There is no prior art, nor proven commercial product for matter of
composition which will be a satisfactory alternative roof water
proofing system. Heretofore AAC roofs were forced to use
conventional roofing materials which are labor intensive, costly,
add tremendous weight to roof system, and are for the most part
environmentally harmful.
[0019] For multi-story buildings, Prior Art U.S. Pat. No. 723,175,
Meyers, Mar. 17, 1903 is only prior art of a remote reference to
ring/bond beam floor panel and corbel ring/bond beam as the patent
shows a wall with floor and roof being incorporated into a single
monolithic unit without a separate ring/bond beam. The processes it
employs of a mold into which concrete is poured is incompatible
with this invention which uses precast pieces.
[0020] The invention's stair system employs a unique support system
which facilitates installation process that is opposed to prior art
(U.S Pat. No. 2,615,325, D. S. Seeber; U.S. Pat. No. 1,573,043, S.
de Cola; U.S. Pat. No. 1,081,074, F. A. Winslow) as this invention
uses no internal steel reinforcing, internal interlocking mechanism
or parts, nor requires a separate support system in mid
section.
[0021] U.S. Pat. No. 5,143,498, Whitman, Sep. 1, 1992 has a screw
with a chamber with laterally disposed openings which are to
disperse liquid sealant. The article of manufacture varies from
invention's auger "R" screw in its primary, and subsequent claims,
as its process is to secure simple roof coverings to roof Its
design is constrained for primary purpose and so renders it useless
for purpose "R" screw serves of replacing rebar by structurally
binding large cementitious products together. The Whitman screw has
a single chamber for dispersing sealant which attaches to rubber
material as material presses against openings and exterior wall of
screw's shaft, which may work for it as it has a screw head which
remains exposed outside material and a tight configuration of
threads ideal for rubber, but "R" screw has a counter sinking head
and while employing threads and mortar to bind, it is unique in
that it has a shaft of multiple chambers serving distinct functions
and process of enlarging opening around shaft for mortar to fill
and so creates one monolithic cementitious product. U.S. Pat. No.
5,249,899, Wilson, Oct. 5, 1993employs a shaft for dispersing an
adhesive through openings located in a recessed thread which works
for it since is used for pre drilled, machined metals, but would be
useless in cementitious product as dust would clog. U.S. Pat. No.
5,516,248, DelHaitre, May 14, 1996 has a plurality of outwardly
projecting serrations which burr into the work piece for self
locking, but the design is limited to that sole use and design is
counter productive in a cementitious material. Standard rebar
requires drilling a hole, inserting rebar and then mortar, and in
method cannot hold inclined pieces in place.
[0022] Invention's nail "N" screw has no individual prior art
references and combination of references clearly fails obviousness
as un-suggested combination of a nail and screw for both are
individually complete and take different approaches. References
further teaches away as threads of normal screws would interfere
with process of nail and nail would not have necessary holding
power in AAC, so screw and nail normally result in inoperative
combination without necessary modifications being made.
[0023] Fire Door prior art required different materials (steel) and
greater cost with less results.
[0024] While the machines in general have many references in prior
art, the process employed by invention are completely unique, and
the machines are superior to prior art in their required
modifications.
[0025] While there are many references to prior art for tools of
routing and reciprocating saws with plunging process, U.S. Pat. No.
5,682,934, Rybski, Nov. U.S. Pat. No. 4, 1997; 5,240,052, Davison,
Aug., 31, 1993 references are closest related to this invention,
yet they are more complex, confined to independent actions
performed on individual pieces at a work station requiring pieces
to be later combined with other pieces at site, and are restricted
by complexity of guide or design's dimensional limitations as
systems lose feasibility when enlarged so cannot create and finish
large openings and/or architecturally finish large surfaces of
permanent placed, vertically positioned structural material.
[0026] U.S. Pat. No. 721178, E. P. Golden, Feb. 24, 1903 does not
apply to joint finishing tool as it is for process of removing a
prescribed depth of material surface and not just cleaning off an
excess of a different material from surface, the patent shows it
has two wheels to each side of blade vs. one elongated wheel which
serves additional function of smoothing out and imprinting residual
material, FIG. 4 shows pressure is exerted on rear positioned blade
vs. on rear rolling pin like wheel which drives neutral front
positioned blade.
[0027] U.S. Patent Planchon, Mar. 22, 1995 shows a reciprocating
saw blade with unique tip for starting a hole and cutting, but not
a good method for holding tool in position while blade starts hole
as one of problems will be maintaining blade in starting hole
without opening template guide and tool guide arms. The none of the
blade designs allow for same structural strength at tip for current
art's blade has benefit of blade strength gained from center of
blade continuing to point while all prior art has curves and off
center points, except for FIG. 10 E, but it lacks teeth on either
side of blade at that point which is important for working with
AAC. Invention has same blade dimensionally as Planchon's FIG. 3
referenced prior art, but is modified differently and additionally
has unique design of directionally neutral teeth on back, which is
quite different than U. S. Pat. No. 3,680,610, Lindgren, Aug. 2,
1972 of oppositely disposed cutting edges which would hinder
current art's penetrating thrust cut. U. S. Pat. No. 2,646,094 F.
S. Russell, Jul. 21, 1953 has a unique blade and tool to assist
guiding but sacrifices benefits of direct perpendicular entry.
[0028] It is now understood that all prior art and standard
industry methodologies employ complex, expensive and labor
intensive combinations of concrete with heavy duty steel
reinforcing and structural support systems/beams which employ
complex steel fastening systems.
OBJECTS AND ADVANTAGES
[0029] Present invention was forced to develop new processes,
machines, articles of manufacture and compositions of matter for
the effective use of cementitious AAC panels, blocks and shapes for
the construction of environmentally friendly habitats. Upon review
of Introductory Figures of Prior Art/Current Methodology, it will
be noticed that there is not one component which is not either
completely unique or modified in such a manner that the resultant
process is completely new. Entire structural habitat can be
constructed of cementitious product without use of steel support
beams, interlocking steel brackets, bolts or other common steel
parts (only rebar as building code requires), gutters, down spouts,
wood trim, casing, and/or molding, nor conventional roofing
materials, yet has the same degree of functionality as a
conventional dwelling with these features.
[0030] It was discovered that large, precisely dimensioned elements
of AAC allow for rapid construction as compared to conventional
brick and cmu (concrete block). Their greater dimensional accuracy
requires less on site adjustment. The combination of large size and
dimensional accuracy allows greatly increased productivity. Due to
the light weight of AAC, reduced equipment demands are
realized.
[0031] The walls employ processes of minimizing vertical blocks.
There are two wall block sizes: mini-wall and wall block. Their
differing contributions to wall process will be detailed later. But
each wall block has invention's utility channel and is coordinated
with other blocks of invention's processes. Each block serves a
specific function in the wall itself as well as replacing as many
as four separate items required in current construction.
[0032] Invention's process of constructing walls of cementitious
blocks, such as AAC, is superior in minimal quantity of two
vertical components (wall block and top block-with casing block for
openings) and three vertical components (base block, mini-wall
block and top block-with casing block for openings), structural
pieces are pre-finished and simply installed as specified (base,
casing, top, crown), are constructed so utilities are inside walls
which have finished surface including architectural effects ready
for painting.
[0033] Openings for windows and doors use present art's casing
block with utility chase system and are dimensionally located with
components of this invention's process on one foot centers so
entire dwelling is an unified dimensional process thereby a
standard 8' high wall uses three components vertically and
horizontally can have virtually no waste. Invention's alternative
process of wall block system allows for all advantages of vertical
three block system with less labor as requires only invention's
utility channel slot at base which coordinates with utility channel
in other articles of manufacture such as casing blocks, etc.. To
fully appreciate wall block system, to be cost effective in
manufacturing and field requires adding 6" of length to AAC
industry's standard 20' slurry mold so three full lengths of 82"
wall blocks and matching casing blocks can be produced without
waste.
[0034] Casing blocks, etc. are horizontally dimensional for 1' and
2' center construction. Single wall block is not called a panel as
steel reinforcing is not required which is substantial savings.
Casing blocks can be omitted and architectural effect added into
wall blocks and Top Block using invention's tools.
[0035] One example of an advantage of invention over prior
methodology of AAC construction and prior art of CMU block, by
using the traditional solid blocks and/or panels there was no good
means to provide a finished interior wall without first using wood
furring strips and externally positioning electrical utility boxes
and wiring which further meant that wood studs and sheetrock or dry
wall panels were required; consequently basically requiring two
wall systems, or, alternatively routing and then inserting conduit
and then having to repair walls. All this added substantial extra
labor and material costs to the construction using AAC panels and
blocks. Current art's internal "utility channel" system allows all
utilities to be placed inside wall during construction and with
special "fishing curve" and "multi conduit" inserts allow utilities
to be placed within wall even after construction. The current art's
utility channel system, inserts and architectural finish provide a
structurally superior finished wall with surface simply requiring
paint and/or wallpaper as a normal finished sheetrock wall. Current
art eliminates all labor and/or forest materials of constructing an
additional wall system. Current art even eliminates need for
finished wood trim by architecturally finished blocks and
invention's tools which are designed to finish vertical, and even
upside down, surfaces. Current art's unique wall block system has
not only saved labor and materials as compared to conventional AAC
construction, it has actually made AAC less expensive and labor
intensive than standard construction materials and
methodologies.
[0036] The top course of a wall is constructed using top block/beam
which is dimensionally sized at +/-16". It can be manufactured as a
block or a continuous beam, as it can be reinforced and even house
invention's air duct system. An industry standard 2' wide panel can
be substituted for top block, as wall block's unique shape is
critical for process.
[0037] A common design problem is resultant gap between the top of
a wall where it meets a sloped roof The crown block with sloped top
fits perfectly into this space and allows for architectural
continuity. The crown block allows for sloped roofs and, if left
with a level top, even additional floor systems to rest on
architecturally finished structural components.
[0038] As previously noted, AAC buildings can be very energy
efficient. A recent study in the U.S. shows that an 8" AAC wall
performs better than a conventional 2".times.6" wood stud wall
system with R-30 Insulation. AAC is ideal for variable temperatures
so that the outside temperature is dissipated by change before it
can permeate block and effect interior. The only disadvantage to
AAC's thermal insulate value is in a location where there are
continuous days of below freezing temperatures as occurs during
winters in northern United States and Canada, the cold eventually
permeates the AAC block. A test in Pennsylvania not using current
art for AAC, showed when AAC is exposed to a constant temperature,
such as freezing, over a period of time it was found that a
winter's heating expense was the same as a standard 2.times.4 wood
frame home. This is one reason why AAC plants are presently located
in only in Southern areas, an ideal climate of moderate,
fluctuating temperatures. Current art solves this problem through
its temperature transferring system manufactured in blocks and
panels and is available for climates requiring it. Warm or cool air
is simply circulated through holes in exterior half area of blocks.
The manufacturing of transfer channels is unique in that the tubes
inserted into the pan mold are two conical tubes with threaded
ends, one male and one female, which after curing are separated by
tool which is inserted into larger end and engages indentations and
is twisted to unscrew tubes. The purpose for conical shape is
ability to ease withdrawing longer sections of pipe from
cementitious material thereby enabling even 20' lengths to be more
easily removed.
[0039] The utility chase and block wall systems are only a few of
numerous other embodiments and claims of this application which
each individually and combined address specific areas of
improvement in AAC construction.
[0040] The structural beam system is placed on walls and is unique
in being constructed of reinforced AAC or alternatively can be
comprised of two cementitious materials, having a center fiber and
steel reinforced concrete and outer casing of AAC which accepts "R"
screws, flange bar and/or hollow bar, which are used to fasten roof
panels to beams.
[0041] The beams can have reinforcing center formed by two halves
with longitudinal slots joined and filled, even HVAC duct and a
utility channel can be placed inside so trades simply pierce AAC
where desired openings are to be located.
[0042] Currently the AAC industry does not use AAC for its roof
systems in residential application because the required structural
steel support beams, etc., rendered it impractical, so industry
methodology is to attach a conventional wood and asphalt shingle
roof on top of AAC walls. Current art is able to feasibly employ an
entire AAC roof system with no steel I beams, support columns,
brackets, braces, bolts, etc.. The structural beam system allows
for all conventional roof designs to be possible, which was
previously thought unfeasible with cementitious products due to
weight, fastening systems and difficulty of working with
product.
[0043] Invention's roofing system maximizes AAC's innate attributes
by combining structure, insulation, gutter, water deflection, and
waterproofing all in one. One of the more important ideas of
invention is the AAC roof panel's waterproofing system. The AAC
roof panels employ current art's cost effective waterproofing
systems, both systems are environmentally friendly products to
manufacture, and the consumer use of either invention will relieve
landfills of 100,000's of tons of current industry asphalt shingle
refuse currently being dumped every year. The current art is
designed to never have to be replaced, only re-coated every 10+
years. Roof repairs are easily discovered and can be repaired by an
unskilled homeowner. Professional roofers will appreciate ease of
application. Both systems not only waterproof, but also remedy
problem of AAC's requirement for vapor permeability (to be able to
"breathe") so moisture build up does not occur inside habitat.
These are only systems known to be able to be applied directly to
roof surface and still facilitate vapor permeability. System A is a
yet to be developed/discovered and proven, material of manufacture
with following characteristics: a custom roofing material having
the following characteristics: waterproof, climate durable,
chemical resistant, vapor permeable ("breathes",) high modulus of
elasticity (stretchable), durable (10+ year use expectancy), can be
continuously re-coated, can be tinted for various colors, and bonds
well to AAC. System B uses a proven material with invention's mesh
design so that the elastomeric material which is not vapor
permeable can now facilitate AAC's need to breathe.
[0044] The indivisible internalized gutter system is similar in
that it eliminates costly additional gutter systems which must be
maintained and replaced. The water deflection system not only adds
aesthetic enhancement but provides process through its unique
reverse (upward) angles to cause water to separate from face
preventing unsightly runs as well as help dissipate negative effect
of water runoff. The gutter down spout box eliminates need for
unsightly down spouts and add architectural accent. Because of new
roof system interior space is greatly increased by vaults as attic
insulation is not required.
[0045] When going multiple stories, invention's ring/bond beam
floor panel eliminates several time and material consuming steps.
The floor panel has unique modification of top row if reinforcing
stopping 1' short of panel end (same as for roof panel for gutter
system). This allows invention's ring/bond beam slot to be
manufactured. Construction is simply placing beam on top of wall
with panel end flush to exterior wall face, inserting required
rebar into slot, installing "R" screws through slot into wall
below, which screws engage other reinforcing in panel. The heads of
screws can be left protruding into slot and rebar tied to them,
then add mortar and immediately next course of block, and continue
on with next wall. This eliminates all the following current
methodology: 1) place panel end short of face of exterior wall, 2)
mortar a block flush to face of exterior wall leaving a gap between
panel end and block, 3) place rebar into gap and add lots of
mortar, 4) wait day for ring/bond beam to set and then continue
construction.
[0046] An alternative improvement in time and costs for multiple
story construction is method of constructing walls without laying
floors or roof until all walls are constructed. This method saves
cost of crane rental waiting between floors or having to make
several trips which can add up to thousands of dollars, as well as
additional costs of down labor time for wall crews waiting for
crane to finish. The method is for a crown block to be used which
protrudes into interior area and forms a ledge for supporting floor
system. When all walls are constructed crane simply sets all floor
panels into interior area and roof panels onto crown block ledge,
all in same day by use of invention's "R" screws. The crown blocks
serve as ledge as well as architectural finish.
[0047] Corbel ring/bond beam is similar, as wall face is routed,
using invention's routing system, to receive a precast, reinforced
AAC beam. Simply mortar and fasten into place using "R" screws and
then floor or roof can be set on corbel ring/bond beam. This
process using unique articles of manufacture allow for quick,
strong permanent placements of floor and roof panels where before
an entire wall assembly system was required.
[0048] Stairs providing access between floors are now able to be
cost effectively constructed of cementitious material which
immediately gives fire protection. Stairs will not creak and have
benefit of muffling a lot of the noise transmitted by standard wood
stairs. Current methodology for constructing stairs, especially
curved and suspended stairways, require a very skilled craftsman
but now unskilled labor can construct a superior stairway in less
time.
[0049] Invention's "R" screw is an indispensable article of
manufacturing which facilitates many of invention's processes.
Auger type "R" screw now makes it possible in one motion to set
steel reinforcing into cementitious product without pre-drilling a
hole and having to wait for mortar to set. An example of one
advantage, a roof panel set on a {fraction (8/12)} pitch can be set
in place with "R" screws into wall and invention's beam support
system and left with no other support. "R" screw locks all pieces
together with threads and counter sunk head. An entire roof system
can be installed, then worker come back and fill all "R" screws
with mortar at end of day for them to set up overnight. Next day
roof is waterproofed.
[0050] A few nuances of "R" screw are advantage of invention's
flanges on screw head are to gouge out AAC so head can counter sink
and simultaneously help lock in place. Unlike any other screw, the
"R" screw has ability to be drilled very close to surface without
breaking AAC apart because of its auger process alleviating
pressure which a standard solid shaft creates. The chambers' unique
design actually allows mortar and screw process to make one
monolithic piece of separate pieces in one step.
[0051] Invention's alternative, the flange bar, is a modified rebar
with most of the advantages of "R" bar except it requires pre
drilled holes. Invention's flange bar allows direct bonding and
reinforcing as code requires with superior results of: centering
rebar in hole, allowing mortar to fill hole around rebar, secure
rebar directly to cementitious material, hold cementitious pieces
in place by flanges imbedded in walls of hole preventing shifting
movements, flanges greatly increase holding power. The "R" screw
has advantage of one step process while flange bar has less
expensive manufacturing costs and can be cut at any length at a
point removed from a flange so that hammer drill can be placed over
shaft and shaft used as a bit.
[0052] A hybrid of both "R" screw and flange bar is hollow bar
which combines best attributes of both inventions into one unit. It
uses invention's cutting device which in cutting uses a crimping
action that results in serrations which through bar's twisting
action grind AAC into dust and force into hollow core. It has a
helix-action with auger flanges which leaves slots for special
epoxy (not regular mortar) to be inserted around bar.
[0053] Invention's nail "N" screw The result is synergism in that
now one item replaces two previously separate processes with the
benefits of both and modifications eliminating detriments. A
problem with fastening items into a cementitious product is that
the cement is not like wood which holds by a constant expansion
pressure upon inserted object, cement holds by a gripping and/or
binding to concrete. Therefore when object is removed it can rarely
be reinserted into same hole with effective holding power. The "N"
screw overcomes this problem by gathering dust in its tip which
binds, by prongs near head which pierce and hold, torque more
pressure via screw head and by ability to reinsert finish nail in
hollow shaft and re-explode tip. While prior art, such as Helifix,
has advantages of piercing and twisting to hold in AAC, it requires
long sections of shaft to work effectively and still wiggles and
can work free without mortar. The "N" screw has variable degrees of
hold, and via nail exploding tip, has unique process of being
permanently set and still retain ability to be removed without
damage to AAC or fastener and then even re-used in same hole.
[0054] Door slabs can be composed of AAC giving great fire safety
and sound insulation to rooms. As AAC is non-combustible, current
art even has an AAC door which is unique allowing a four hour fire
rated wall having a specially designed opening.
[0055] Tools biggest advantages are ability to be used on vertical
plane surface and enabling unskilled workers to make finished
openings and other modifications in thick walls, as well as
finished trim designs. Most of the tools combine steps so that what
required two or more tools and several processes in prior art can
now be done with invention's machines, articles of manufacture and
processes with one tool and in one step.
[0056] Invention's air duct system uses AAC insulate characteristic
and duct's structural reinforcing for unexpected result of a
manufactured structural component: 1) an internal duct system which
is installed during construction of habitat as it is an integral,
structural part of habitat, 2) is an insulated forced air duct
system which reinforces cementitious material, 3) reduces volume
weight of top beam, 4) requires no additional framing, etc., to
hide it, 5) uses process of varying opening sizes custom installed
at site to regulate required air supply. Blocks and beams can also
be used with a standard sized hole becoming the air duct with no
other duct work required.
[0057] The beauty of current art is its ability to emulate the
aesthetic appeal of industry's standard habitats while being
composed of a completely different, unique cementitious material.
It is current art's synergy allowing it to overcome problems
preventing AAC's acceptance by construction industry. Each of
current art's embodiments is crucial to whole as it is synergistic,
i.e.: without support beam system, roof panel system would not
feasible, and without "R" screws and light weight roof waterproof
coating system the support beam system would not be feasible.
[0058] It is very important to note that it is the synergy of the
many previously undiscovered and unanticipated attributes of
current art's combined systems (manufacturing, wall, roof and floor
support, roof coatings, fasteners, tools, etc.) described herein
that culminate in a completely unanticipated result of a superior,
environmentally friendly cementitious habitat, so that the habitat
as a whole becomes a unique, new item.
[0059] The manner by which the system hereof applies the processes,
machines, articles of manufacture and compositions of matter will
become apparent in the description which follows, particularly when
read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0060] FIG. 1 is an exploded perspective view of a partial, two
story cementitious dwelling constructed in accordance with the
teachings of this invention, further showing numbers identifying
specific areas of the dwelling and their relationship to the later
series of Figures.
[0061] FIGS. 1A-1C are front elevations of prior art.
[0062] FIGS. 1D is front elevation and 1E is side elevation for
manufacturing blocks of invention.
[0063] FIG. 2A is a partial perspective view of a wall, with a door
and a window opening, using in section A: base block and mini-wall
block combination, top blockbeam and optional curved block
wall.
[0064] FIG. 2B is a continuing partial perspective view of a wall,
with a door and a window opening, omitting base block and mini-wall
block and substituting them with a wall block and big base
block.
[0065] FIG. 2C is a continuing partial perspective view of a wall,
using a second story on floor panels, with a door and a window
opening, substituting top block with top beam over openings and
omitting wall block and substituting full wall blocks.
[0066] FIG. 2AA-1 is partial perspective view of an AAC base
utility block, preferably used as primary course, along with detail
drawings of the block to illustrate various aspects of the AAC
block.
[0067] FIG. 2AA-2 is a partial perspective view of base utility
block with variation of utility channel having a front entry
joining a casing block.
[0068] FIG. 2BB-1 & 2 are two partial perspective views of wall
blocks which are routed with a vertical chase and shaped edges.
2BB-1 has example of architectural design routed on face by tools
of invention.
[0069] FIG. 2CC is a partial perspective view of an elongated,
vertically oriented casing block, showing incorporated utility
chase and a curved insert to facilitate pulling/fishing electrical
wiring or cable through the blocks. It is adjoining a finished wall
block.
[0070] FIG. 2D is a partial perspective view of a top block which
dimensionally compliments wall block to allow precise height
dimension for doors and window openings. It shows this invention's
casing and utility channel as well as industry standard slot for
reinforcing.
[0071] FIG. 2DD is top block beam which combines functions of a
header for openings and a bond beam for wall and can house utility
channel and invention's enclosed, insulated duct system.
[0072] FIG. 2E is a partial perspective crown block, having crown
molding, showing a tapered top wall with a longitudinal slot and
crown block used as floor support system.
[0073] FIG. 2F are two views showing a special molded plastic
insert to convert a utility chase into a multi-chamber chase.
[0074] FIGS. 2G and 2H are several views illustrating curved AAC
blocks and manufacturing procedures.
[0075] FIGS. 21 and 2J are a series of views showing a preferred
manner of providing temperature transfer within an AAC
dwelling.
[0076] FIGS. 3A through 3F are different views illustrating various
aspects of a roofing Beam Support system according to this
invention.
[0077] FIGS. 4A through 4D are different views illustrating various
aspects of this invention's water proofing system applied to roof
and invention's moisture removal system.
[0078] FIGS. 5A and 5B are two views showing further this
invention's panel bond beam system.
[0079] FIG. 5C is a cross sectional view of a wall detail showing
invention's panel bond beam in conjunction with invention's wall
block and top beam with duct system, routed with casing block
design for spanning opening.
[0080] FIG. 6A is a partial side view illustrating invention's
corbel bond beam system which allows floor and roof panels to be
secured directly to a cured cementitious mid wall sections.
[0081] FIG. 6B is a partial side view illustrating invention's
crown block/metal ledge floor support system.
[0082] FIGS. 7A through 7C are different views illustrating a
preferred auger screw, "R" screw for securing AAC materials.
[0083] FIGS. 7AA through 7CC are different views illustrating a
preferred hollow bar, a hybrid of "R" screw and flange bar which
replaces standard rebar. Also invention of a tool used to cut,
crimp and create serrated ends in Hollow Bar.
[0084] FIGS. 7AAA through 7CCC are different views illustrating a
preferred flange bar, invention's modified rebar.
[0085] FIGS. 8A through 8D are various views illustrating a dual
functioning "N" screw for attaching items to AAC materials.
[0086] FIGS. 9A and 9B are selected views of an AAC stair case
assembly.
[0087] FIG. 10 is a top view of an improved fire wall with opening
and door.
[0088] FIGS. 11A through 11D are various views of a routing
tools.
[0089] FIG. 12 is a side view of a hand held utility chase cutting
tool.
[0090] FIGS. 13A through 13D are different views of cutting
implements for AAC matenals.
[0091] FIG. 14 is a perspective view of a crushing apparatus for
transforming scrap pieces into dust for environmentally friendly
disposal.
[0092] FIG. 15 is a joint scraping tool for use on removing excess
AAC mortar from joints.
[0093] FIGS. 16A and 16B are two views of tool for making openings
in AAC materials.
[0094] FIGS. 17A through 17C various views of tool for inserting
wires into utility channel and fastening in place.
[0095] FIGS. 18A through 18C are various views of duct system.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0096] Looking now to the Figures to help illustrate and describe
the method of this invention, the introductory Figures of prior art
and invention are for review and comparison to invention. The first
figure is an exploded perspective a cementitious habitat (FIG. 1)
having references to various components of invention, i.e.; FIG. 2,
FIG. 3, etc.. The Figures represent processes, machines, articles
of manufacture and matters of composition which culminate in a
constructed habitat. The cementitious material can be any material,
cementitious or other, which invention can employ, but in this
explanation will be represented by AAC.
[0097] AAC blocks are typically formed by first preparing a slurry
of the AAC mixture and placing same into current industry standard,
large mold (FIG. 1A prior art) measuring approximately 4' wide by
24" deep and 20' long. After the slurry sets, the form may be
lifted out of the tray and cut into the desired sizes. Industry
standard panels are always steel reinforced and sized 2' wide by
+/-8" thick (FIG. 1B prior art) and when used for walls are +8"
long (for vertical height). Most blocks are usually 8" wide by 8"
tall .times.24" long (FIG. 1 C prior art) with only one USA plant
manufacturing a jumbo block of 2'.times.4'.times.8".
[0098] Invention's system shows manufacturing modification of
8".times.16"(FIG. 1 D) for top block (FIG. 2 D, 206) which is
coordinated with wall block of industry standard 2'.times.4' but
new dimensional length of 82" which requires modifying mold length
(FIG. 2E) by additional 6", from prior art 240" to 246", so three
lengths of 82 wall block as well as coordinated casing block can be
manufactured without waste. Accordingly, one preferred size is wall
block (FIG. 2B, 200B) having an elongated dimension of +/-82", and
a short dimension of two (2) feet. This previously unconsidered
elongated dimension allows for construction industry standard
pre-hung doors with only jambs to slip flush into invention's
casing block system so that no additional wood trim is required or
customizing blocks at site.
[0099] Alternative curved blocks (205) manufacturing (FIG. 2G &
2H) are manufactured by wires, as known in industry, being modified
as being connected to a computerized, mechanical arm which cuts AAC
as pattern and arrows describe. There are presently no curved
blocks being manufactured anywhere in world to my knowledge.
[0100] For more frigid climates, invention's temperature transfer
system (FIGS. 2I, 2J) which is manufactured (FIG. 2K) into AAC by
tubes inserted into mold. The manufacturing of transfer channels
(54) is unique in that the tubes (251) inserted into the pan mold
(250) are two conical tubes with threaded ends (255), one male and
one female, which after curing are separated by tool (253) which is
inserted into larger end and engages indentations (252) and is
twisted to unscrew tubes. Optional flange (254) on female conical
tube holds it stationary while male tube is first unscrewed and
withdrawn. The purpose for tool and conical shape is ability to
ease withdrawing longer sections of pipe from cementitious
material, as tool employs fulcrum to initially break tube free and
then conical shape allows for no resistance as withdrawn. This now
allows for extremely long voids/channels to be easily created. Also
ends the need for coring of individual blocks as is currently done
since blocks cut with void suffice.
[0101] The temperature transfer system (TTS) allows for excess
heat, usually wasted and/or lost, to be realized and circulated
(58) via air channels (54) throughout exterior walls (200A) and
panels (40) of habitat. System can employ a geothermal (56) and
solar (55) storage tank (52).
[0102] After the cementitious materials are prepared, construction
can begin. Initially a superior concrete foundation, or footer with
slab is poured, as known in the art, to present a base for
receiving the AAC blocks. The blue prints, as known in the art, are
measured and laid out on floor by a qualified individual. Correct
designations are marked on floor for openings, block type, location
of outlets, etc.. From this point a small crews of four unskilled
workers using a level, trowel and drill can construct a quality
habitat in half the time of a comparable "stick built".
[0103] A first step in constructing invention is the wall system
(FIG. 2, FIGS. 2A-2AA). The process comprises selecting a
discontinuous first course of elongated AAC base blocks (FIG. 2A)
for placement on a pre-built foundation. A base block (FIG. 2A,
201, and 2AA 201) is one solid structural finished component which
is load bearing, utility receiving, architecturally finished and
uniquely dimensionally processed. The respective +/-10" tall
.times.+/-9" wide blocks are oriented with a longitudinal slot,
called a utility channel (202), exposed along the upper surfaces
or/and along vertical face (FIG. 2A, 202) thereof, into which
utilities (217, 216, 123, 124) are inserted and later covered by
subsequent course and/or preformed, dimensional type of
cementitious board (FIG. 2AA, 229) which fits perfectly between
notch (225) at base and start of architectural finish (208) so that
there is no seam and it becomes integral part of design.
[0104] Alternatively, the base block (FIG. 2A, 201) may be omitted
and the mini-wall blocks (200A) substituted with wall blocks (FIG.
2B, 200B). Wall blocks have a custom notch design near base (FIG.
5B) which is covered by flooring and/or optional base board.
Another alternative (FIG. 2C) is omission of casing blocks and
instead wall blocks (200B) are architecturally routed, including
utility chase. All blocks work with invention's utility channel
system.
[0105] Whatever block process is used, the blocks are cemented into
place and leveled, except where door openings are located (212).
Initial leveling is critical as all subsequent courses of blocks
can be laid directly on the base course without further delay of
subsequent leveling since AAC blocks are dimensionally
accurate.
[0106] Continuing description using base block (FIG. 2AA-1 &
2AA-2, 201), as apparent, the purpose of the slot (FIG. 2AA- 1,
202) is to receive utilities, i.e. electrical wiring (FIG. 2AA- 1,
217). After utilities (FIG. 2AA-1, 217 & 226) and all inserts
(214 & 215, etc.) are placed in utility channel (202), then a
thin cover composed of plastic or paper (18) is placed over utility
channel (202) opening to prevent special AAC mortar (19) from
falling into utility channel (202) when constructing subsequent
blocks and panels, as mortar would obstruct future installments of
utilities which can be pulled/fished. Additional utilities can be
placed on top of Base Block (FIG. 5A, 202) which are accepted into
utility channel (202) in base of second course (200). The base
blocks (201) are +/-10" high and +/-1" wider than mini-wall blocks
(200A) and have architectural base board finish (208) which
recesses and reduces base block to width of subsequent mini-wall
block (200A). Base block (201) also has optional variably sized
recessed notch (225) at base for overlapping flooring. Reference
numerals (208 & 225) create the invention's unique attribute of
being architecturally and functionally equivalent to a base board;
so even while housing utilities, it is structural and functional as
well as having ornamental finish.
[0107] Outlets (216) are located into base block (201) by cutting
opening using special roto plunging tool (FIG. 16A, 167) and
template guide (163). Outlet boxes, etc., fit exactly into opening
formed by template guide (163) and are fastened into place using
nail "N" screws (FIG. 8, 80) or adequate means.
[0108] Thereafter, a method of vertically orienting and cementing
comparably designed, plural mini-wall blocks (FIG. 2A, 200A) onto
at least certain of the first course of blocks, where the height of
each block is a multiple of a nominal dimension of "X", where a
typical mini-wall block is 6', and "X" equals 2'. Mini-wall blocks
(FIG. 2A, 200A) are preferably 72" high, do not require wire
reinforcing as does standard wall panels which have manufacturing
difficulties and additional costs, but have advantages of panels in
quick installation and can be routed (FIGS. 2BB-1 & 2BB-2).
Mini-wall blocks (200A) can have utility chase system (202)
integrated into ends and sides to form horizontal and vertical
utility channels (FIGS. 2BB-1 & 2BB-2).
[0109] Alternatively, to mini-wall blocks mounted on base blocks is
method employing wall blocks (FIG. 2A & B, 200B). Wall blocks
are +/-6'-10" tall so top equals height of standard door with
frame. Wall blocks which have hidden utility channel machined into
bottom (FIG. 5C, 200B). Additionally, tools (FIGS. 11) are able to
architecturally finish (FIG. 2BB-1, 208A) wall blocks (200B) with
casing design and utility channel allowing for omission of casing
blocks.
[0110] In any case, thereafter, plural elongated casing blocks
(FIG. 2CC, 203) preferably the height of wall blocks, are
vertically oriented around the first horizontal course where
openings (212) for doors and windows are to be placed. Invention's
casing blocks (FIG. 2CC, 203) are used for window and door openings
and are structural, integral components of wall which have
architectural finish (208) and can have utility channel (202).
Electrical switch boxes (216) can be located in casing blocks (203)
at door openings and are constructed similarly to outlet boxes
(203) in base blocks. The slots for utility channel are of such a
width that when windows and doors are installed their frames
conceal slots and only caulk or shoe mold is required to finish.
The top beam has casing block's architectural finish where openings
are located.
[0111] Casing blocks have vertical and horizontal "X" factors.
Vertically, the same dimensional vertical "X" equals wall blocks
(200A & 200B ) so their top heights are level. This level
height is optimized at +/-6'-10" to match finished doors and
windows. Horizontally, casing blocks are "X" equals 2' or 1' so
that either 17+/-" wide for full size openings (ex: 36" (3 '-0"
door) +2+/-" (3/4"+3/4" frames & gap), +34"+/-(two 17" Casing
Blocks)=1' center), or 14" for half size openings (ex: 30" (2'-6"
door)+2+/-" (3/4"+3/4" frames & gap), +28"+/- (two 14 " Casing
Blocks)=1' center). The walls are constructed on 1' centers with
minimal waste. By disciplining design using matching units a wall
can be constructed without having to cut 2' wide wall blocks. Doors
and windows with 3/4" jambs can slide under subsequent course and
into opening, requiring nothing else to flush finish other than
trim or caulk, as the architectural finish (208) on blocks blend
into door and window frames and become one architectural unit when
painted. Conventional finishes have architectural finish added onto
wall and so protrude away from wall, while present invention has
finish recessing into structural walls as walls are thick enough to
use the invention's time and material saving process.
[0112] A simplified wall process is for invention's tools to
architecturally finish (243) wall blocks (FIG. 2C, 200C) at
openings and create utility channel (202) so that a casing block is
not required, as wall block has features of casing block machined
into it. The width of opening is flexible so that only top
block/beam (206) acting as header spans or big base block (FIG. 2B,
241) used under window are cut to fit. Big base blocks (241) are
basically wall blocks turned horizontally so all window openings
can have standard height from floor of 24" and variable width. This
is preferred method of all options.
[0113] Where casing design and base moulding design meet (FIG.
2AA-1) an optional prefabricated architectural insert (231) fits
into slot and provides continuation of architectural finish (208).
Where the utility channel (202) intersects with other blocks or
changes angles, in a preferred embodiment, a curved insert (FIG.
2A, 214) sized to be slidably placed into the longitudinal slots
(202), may be placed into perpendicularly converging utility slots
to provide a continuous curved path for easy wiring of the erected
structure in future after direct access is closed off. By this
arrangement, and with pre-positioned openings extending to the
inside from the longitudinal slots, the entire structure may be
suitably wired with recessed utility boxes to present a wall
surface suitable for finishing.
[0114] Where architectural finishes (208) for casing blocks (203)
and top block/beam (206) meet, an architectural insert (231) is
placed to cover incompatible intersection.
[0115] Top block beams (FIG. 2D, 206) are placed as a horizontally
oriented course of comparably designed AAC blocks, where the
longitudinal slots (202) over the openings, such as doors and
window openings, and casing finish (208) are exposed downwardly
toward the opening. An optional architectural finish (208) can give
a crown molding appearance (208) to top block where floor panel
(FIG. 5A, 59) will rest on top block (206). Top block are
preferably manufactured as beams and have enclosed air duct system
and reinforcing channel which coordinates with roof's beam
system.
[0116] Thereafter, the top most course of wall, comprised of
invention's +/-16" top block beam (206), is placed on wall blocks
(200 A & B, not C) and/or casing blocks (203). Top block can
have variation of architectural finish (208) as casing blocks for
windows and doors, as well as continuous design to equal crown
moulding, which allows for one structural component, top block, to
replace four standard pieces: header, filler, casing and crown.
Additionally, top block is of specific dimension so that base
block, mini-wall block and top block form a minimum 8' high wall. A
unique feature of this invention is the provision of an effective
method to construct a dwelling using primarily precut and sized
blocks of cementitious material. By the use of such cementitious
blocks containing specific dimensions unique to this invention
process and not in prior art, an 8' high wall can be constructed
using only two blocks (or three if using base block) which blocks
have specific, unique design and functions beyond just dimensional
advantage. Blocks are additionally modified with predetermined
slots and openings termed utility chase system for utilities, i.e.
electrical wiring, plumbing, etc., facilitating construction of
habitat. Further, also employing tools for finished architectural
routing for either the base block, casing, features for openings,
and/or crown block, smooth finished walls are transformed into
architectural finished walls with no additional materials.
[0117] For rounded walls and/or corners, if desired, one may employ
arch shaped rounded blocks (FIG. 2A, 205), where the rounded shapes
of such blocks may be accomplished by inserting rounded mold (FIG.
2G) into industry standard AAC pan. Alternatively, a computerized
mechanical arm may run wires through cementitious material (FIGS.
2H) in a unique pattern producing curved blocks with very little
waste, and which waste is able to be recycled as it is still in
green stage before autoclaving. This finishes wall construction
processes.
[0118] The corbel bond beam system (FIG. 6A) is the present
invention's method to attach floor and roof panels directly into
the mid wall section surface instead of on top of walls which
requires a great deal more construction effort and material. The
corbel slot is formed at manufacturing or on-site field routed
using the tools of this invention (FIG. 12) with different bit. The
corbel bond beam (60), which is reinforced with rebar (35) is set
into slot with mortar and fastened with "R" screws (70), or
invention's alternatives, which engage rebar reinforcing.
[0119] When there are multiple floors, floor panels can be placed
directly on top of first level wall top block/beam (FIG. 5A) with
panel end flush to exterior wall. Floor panels, according to this
invention, may use invention's bond beam slot (50) and auger "R"
screws (70) to effectively replace several steps of prior
methodology. Prior art methodology a bond beam was to first drill
vertical holes into top of wall, then short sections of rebar were
mortared into holes, and thereafter a long, horizontal rebar was
tied off to vertical rebar (35). This necessitated a space between
end of floor panel and a block placed flush to exterior face of
wall. The bond beam was formed in the gap between panel end and
wall block using rebar and mortar. This method required additional
material, labor and days of curing time before subsequent floors
could be constructed. The present invention eliminates several
steps and materials and allows construction to continue
uninterrupted.
[0120] Floor panels (59) hereof have unique bond beam slot (50) by
manufacturing AAC similarly to roof panels for internal gutter
system (FIG. 4B) where upper course(s) of steel reinforcing (52)
stops shorter of panel end than other layers so slot can be routed
and bit not hit reinforcing steel. Rebar (35) is horizontally laid
in bond beam slot (50) and tied to "R" screws (70) and then bond
beam slot is filled with mortar (19) as base block (201), which is
the first course of next wall, is laid.
[0121] An alternative floor support system is (FIG. 6B) for crown
block (207B) or steel plate ledge (207x) to be placed into wall
during construction to support floor system and a space block
(201B) with height equal to thickness of floor panel is installed.
This invention's method allows for wall construction to continue
until all walls are constructed before floors and roof panels are
installed. When floor panels are installed, the gap between end of
floor panel and wall is filled halfway with rebar (35) and mortar
(19) and becomes bond beam. The upper half of gap is left a void
and becomes a utility channel (202) for wires (217) and other
utilities to be inserted. Outlets (216) are placed in floor panel
using invention's method in area void of reinforcing. Finish floor
covers uniquely located utility channel or small gap it can be
filled with additional mortar. When steel plate (207x) is employed
the plate is welded at corners and becomes bond beam and "R" screws
are inserted through holes in plate which engage with floor panel's
reinforcing. Holes in side of plate inserted into wall joint allows
mortar to fasten plate in position inside walls. A small insert
(207y) is used to support next course of space block (201B) level
until mortar sets.
[0122] Where stairs are employed to travel between floors,
invention's stair system is employed as shown in FIGS. 9A and 9B,
which are partial views of stairs made entirely of AAC. There is no
prior art of cementitious stairs being supported only at ends and
reinforced by adjoining steps. All prior art uses either steel
reinforcing throughout or supports in middle of stair, which
extends to ground along total run of stairs. The process for
constructing stairs is completely original.
[0123] The invention's stair system uses cementitious blocks 90
which have an angled slot 91 that corresponds to the desired pitch
of the stairs. The angle support brackets 92 are secured to the
wall at the desired pitch of stairs, which pitch corresponds to
slot 91 in cementitious block.
[0124] Blocks are simply slipped onto support bracket at top of
stairs in gap, see FIG. 9B, reference numeral 93, between brace and
floor and then slid down and mortar 19 to secure onto top of
previous block. Optionally, an "R" screw 70 can be used for
additional fastening. The angle iron 92 with special slot 91 makes
a permanent structural unit. Mortar placed on ends of stairs
additionally bonds stairs to AAC walls. Face of cementitious AAC
blocks can be routed to have a tread 94 and/or other architectural
advantages. The advantages allow for additional safety of fire
proof stairs cases which are devoid of squeaking.
[0125] Thereafter, if there is not to be an additional floor, on
the top most course of wall comprised of top block, a crown block
(FIG. 2A, 207) featuring a sloped top wall (228) is cemented to the
top course. The slope is comparable to the roof slope so that the
roof panels may be supported thereon and secured by suitable
fastening means. FIG. 4B further shows a tapered crown block (207)
secured to the top of the wall for mounting a roof panel (40) and
roof support members. The crown block has a slope equal to the roof
panel pitch and is manufactured by taking a standard base block
width and cutting in half so that mirror sides equal slope pitch of
roof The interior face is routed to resemble crown molding The
result of this inventive technique is a single structural piece of
cementitious material that has architectural attributes of finished
wood trim and is used to bond pitched roof panels to flat walls.
Crown blocks with a level top, instead of angled to the roof pitch,
can also be used to add height and design features to any wall.
[0126] The roof is constructed by first securing AAC roof panels 37
to the roof support beam system, beams 30, 31, 32, where a typical
roof has a plurality of beams arranged in specific load and stress
managing pattern.
[0127] The construction method may be continued by positioning
invention's support beam system (FIG. 3A-3F) onto walls. The
cementitious beams are comprised solely of cementitious material
with steel reinforcing, and optionally can have invention's
reinforcing channel (FIG. 3F, 36). Support beams require only
mortar and fasteners as unique interlocking design (FIG. 3C &
3D) eliminates need for interlocking brackets, bolts, or other
mechanisms. All types of roof pitches and designs, including hip
and valley (FIG. 3A), are now possible for a purely cementitious
roof and support system.
[0128] The supporting beam system with reinforcing channel (36) is
constructed by placing rebar into channel (and utilities), tying
all rebar together, which can include rebar coming from
foundation/slab, then drilling holes into beam and pouring mortar
into beams (FIG. 3F, 38) so that incredibly strong support beams
result. The invention allows for AAC surrounding hard concrete
reinforcing channels to receive fasteners (70) and so secure roof
panels to supporting beam system. Invention's roof system requires
no brackets, braces, bolts, etc., as does all prior art. At most
what may be required are tension tie rods for certain hip roof
designs to give walls extra support.
[0129] The construction process is continued by placing roof panels
(FIG. 3E, 40 & 3F, 40) on supporting beam system. When a roof
is resting on standard 8' wall instead of a second floor FIG. 4B),
then a fourth level of blocks comprised of crown block (207) can be
used. As best seen in FIG. 4B, a series of crown blocks (207),
preferably eight (8") inches in height, are cemented to the planar
surface (229), where the crown block (207) features a slanted upper
surface (228) for receiving an angled roof panel (FIG. 4B, 40). The
panel (40) may be secured to the crown block (207) by "R" screws
(FIG. 7A, 70), and mortar (19) as known in the art, on planner
surface (229). Crown blocks can also be structural for openings
with cavity (227) being filled with rebar and cement.
[0130] The beam system utilizes the invention's optional
reinforcing channels, (FIG. 3F, 36), which can be used in addition
to standard reinforcing to facilitate easy construction and
provides even stronger support due to internal bond beam/utility
channel tying together the entire habitat. Beams can have a squared
edge corrugated pipe (36) inserted into the AAC slurry during
manufacturing. The AAC fits between the square corrugation in pipe
and holds fast and is strong enough to remain intact during initial
construction. The hollow corrugated pipe (36) at site has rebar
(35) placed inside, as well as any utility conduits (26) desired,
which conduits can be accessed for lights, etc.
[0131] Roof beams are erected and fastened so that the hollow core
formed by corrugated pipe, which is termed reinforcing channel
(36), align each other at intersection/joint of beams. After beams
are joined together and set with "R" screws (70), the AAC mortar is
pumped throughout the reinforcing channel system (36) resulting in
an incredibly strong beam system which ties the entire structure
together. This reinforcing channel system also allows "R" screws to
fasten roof panels into the softer AAC portion of the beam.
Optionally, a standard concrete beam can beam constructed and then
an AAC beam adhered with mortar to top of concrete beam so result
is a dual material beam which has softer cement for fasteners on
top and harder, reinforced concrete on bottom. The concrete beams
can be constructed and poured at site with foundations.
[0132] While any type of pipe can make reinforcing channel, the
reasons for using optional corrugated pipe or corrugated, helical
conical mold insert (255) which unscrews from mold, are: 1) the
corrugation gives extra surface strength and adds additional
strength to reinforcing channel when filled with concrete as two
cementitious materials bind against each other; 2) the corrugation
prevents AAC outside and cement inside from separating from pipe
during stress flexing; and, 3) the corrugated pipe allows mortar to
flow throughout entire system as AAC is known to absorb moisture so
quickly that if system had only exposed AAC the mortar may quickly
adhere to channel walls, possibly clogging channel and thus prevent
mortar from reinforcing certain areas.
[0133] The roof panel system is then fastened to the beam system
and roof panels waterproofed. The roof design is identical for both
sections A and B of invention's roof waterproofing system (FIG.
4A). Section A is a perspective of a finished stage using a
different water proofing material (47) than Section B's segment
which is shown at an initial stage in its construction using the
technology hereof. It is important to note that the invention's
water proofing system for roof panels is of four distinct
processes/features, namely: 1) water proof coating, (47 &/or
41); 2) the facia water deflection system (45); 3) integrated
gutter system (44); and, 4) gutter box which replaces down spouts.
The roof's water proofing system is constructed as follows:
[0134] FIG. 4A, section A, (47) is a new composition of matter as
yet to be manufactured or discovered as a roofing material, having
the following characteristics: waterproof, climate durable,
chemical resistant, vapor permeable ("breathes",) high modulus of
elasticity (stretchable), durable (10+ year use expectancy), can be
continuously re-coated so no waste material has to go to landfills,
can be tinted for various colors, and bonds well to AAC. It is
simply applied by spray or roller.
[0135] FIG. 4A, section B as a preferred system, incorporates a
polyester/nylon mesh (42), having alternate sections of a tight
mesh (43) and a loose mesh, and is placed over the AAC panels in
the direction of the ridge down to the eaves. Next, an elastomeric
composition (41) is applied to the mesh, and, as a result of the
porosity of the loose mesh, the elastomeric composition goes
through the loose mesh and adheres to the AAC panels. However, the
elastomeric material will not go through the tight mesh (43) such
that an air channel (47) is created between the tight mesh (43) and
the AAC panels (37). Further, another coat of the elastomeric
material (41) may be applied for extra wear resistance. The
respective air channels (47) allow moisture in the AAC panels to
escape, i.e. breathe. Additionally, the air channels (47) also
function as air is drawn up through the channels from the eaves end
of roof to the top ridge vent (48) by use of naturally occurring
temperature and wind where it may be vented (48) to the
atmosphere.
[0136] The integrated gutter system of this invention uses industry
standard AAC roof panels with a modification in steel reinforcing.
Since gutters (FIG. 4A and 4B, 44), may be routed out of the roof
panel (40), the top rows of embedded reinforcing rods (FIG. 4B, 52)
extend short of the edge similar to bond beam panels (FIG. 5B).
There is no need for all the structural reinforcing at the gutter
location as AAC is strong enough by itself An angled routed groove
(44) may be added to the AAC panels to transmit moisture out of the
roof assembly and act as an integrated gutter system to gutter box
(46) hereof. No prior art of cementitious materials with integrated
gutter systems employ a gravity driven water removal method. All
prior art rely on inferior water pressure method as subsequent
water forces previous water toward down spout box and off the roof.
The prior art's use of water pressure has negative results of
residual moisture remaining in trough which eventually causes water
damage due to debris build up and/or freezing. Invention's down
spout box (FIG. 4D, 46) disperses moisture out and away from
habitat by curved wall and wide slot at base. The interior ridges
and various platform heights of curved wall near slot break up the
mass of water into smaller droplets so as it is propelled out of
box large volumes of water do not overburden any one area too
much.
[0137] Finally, the facia water deflection system (45) is one and
the same material as the roofing and is one continuous piece of
roofing material, specifically shaped to have reversing angles with
a series of sharp angles so it is impossible for water coming off
the roof to run down its face, but rather gravity pulls water off
its face at several different places, which not only deflects water
away from house but also breaks water down into smaller droplets so
it does not damage landscaping beneath. Therefore, facia design is
not just a cosmetic architectural feature, it is an unique
functioning aspect of the roof's waterproofing and moisture removal
system much different than existing plumb facia boards and moulding
which recess with angles but not reversing angles. An integral
functioning process advantage of the finished ends of the roof
panels lies in its water deflection which is multifaceted. The
reversed angle routed end makes it impossible for excess moisture
from the roof to run down face of the panel end/roof facia. This
overcomes two failures of the prior art, namely: 1) moisture
carrying naturally occurring debris running down vertical facia
causes unsightly streaks; and 2) moisture running down facia is
easily blown back toward habitat By means of the instant invention,
the need for additional labor and material of drip edge is avoided,
while adding unique architectural enhancement to the habitat.
[0138] Therefore, the present invention's roof panel design and
process of moisture removal system is comprised of a single
cementitious material identical to the roof and is actually roof
material itself and thus an indivisible component of roof
consisting of two distinct components: 1) a downwardly angled
trough (44) which feeds moisture to a down spout or the down spout
box of this invention (FIG. 4D, 46); and, 2) a facia (45) with
square edges and upward, reverse angle pitches having a multi faced
formed edge of cementitious roof. This roof system is then coated
with either of the two water proofing materials hereof (40 or 41).
Both moisture removal attributes are part of the present
invention's roofing system and work in conjunction with each other
as one moisture removal system.
[0139] Doors are possible with AAC (FIG. 10), so that even four
hour rated fire wall (4) may be possible with an operating door
(100) which is composed of AAC. The door face can have all types of
architectural or decorative effects as a standard wood door. The
wall is composed of standard wall blocks (200 A, B) but uses casing
blocks (203) having custom fire thwarting design and latch system
(101). The door can be held in place by special heat resistant
piano type hinge (103) or the internal hinge (104) hereof, which
has special sliding hinge pin so all mechanical parts are protected
within fire proof AAC.
[0140] Now that the individual embodiments of materials and
structure of habitat are understood, what needs to be explained is
the preferred fasteners and tools of this inventive system. The
auger "R" screw (FIGS. 7-7C) is a preferred method of securing, not
just to fasten, but to actually bond AAC together. The "R" screw
acts as an auger screw and gets its name from the fact it provides
more structural advantages than standard rebar but does so with the
ease of a screw, especially as screw engages any steel reinforcing
in the panels and elsewhere. As noted above, a fastener (70) can be
used to secure a roof beam (30) and/or panel (40) to the crown
block (207).
[0141] One difficulty is that prior art fasteners, such as the
Helifix, can work free over time without mortar holding pieces
fast, consequently if mortar in joints ever failed then system is
in jeopardy. Also, the Helifix is inadequate in size to secure
large, heavy pieces of cementitious material, and due to need for
cement to assist bonding, simply increasing size does not solve its
design inadequacies. To improve the fastening capabilities of AAC
materials, such as the roof beam to the crown block, a new and
unique fastener had to be developed.
[0142] Though different, U.S. Pat. No. 5, 143,498, to Wiftman, and
granted Sep. 1, 1992, teaches a rubber roofing material fastening
device that includes an optional liquid sealer to facilitate the
process of affixing roof items to the upper surface of a roof The
fastening device has a longitudinally extending centrally located
chamber which is coaxially aligned with the longitudinal central
axis of the fastening device. The chamber has a plurality of
laterally disposed openings which extend from the chamber to the
outer surface of the fastening device. The chamber is adapted to
receive a liquid sealant at an opening in the upper surface and
disperse same through such lateral openings. The exterior surface
of the screw shaft is formed with screw threads having a dual set
of helically wound threaded members. The external, most radially
outer portions of the threads are grooved with serrated teeth to
enhance the holding power of the fastening device.
[0143] The "R screw fastener member (FIGS. 7-7C, 70) of this
invention is comprised of a solid core (7 1), preferably "hour
glass" in shape, within an annular wall (72) to define three
elongated cavities, one passing through the center to each side,
and two opposite each other on outer sides separated by the center
cavity. The three elongated cavities create two functioning
processes with the two cavities opposite each other performing the
same process, namely, the center cavity is a mortar chamber (73)
and the side cavities are dust chambers (74). Along the annular
wall there are provided plural openings (75) in communication with
the mortar chambers. Additionally, there are provided plural
openings on the annular wall and in pointed end (78) in
communication with the dust chambers with at least one cut-out
window having a scraper blade (76), which is a portion of the
cut-out of the wall extending tangentially from the annular wall
(72). In operation, the dust chambers (74) captures AAC dust
created by scraper (76), as well as through opening in pointed end
(78). The scrapers (76) serve two functions: 1) to enlarge hole
area around shaft (72) so that an air space is created between the
AAC and shaft (72), which space will be filled with mortar flowing
out of mortar chamber (73); and, 2) remove from the enlarged hole
all lose AAC dust so that mortar flowing out of mortar chamber (73)
has a good surface for bonding. The head portion (77) removably
receiving a square head power screw driver as an air ratchet, which
square opening is an opening through to the mortar chamber and
through which mortar is poured into cavity after driver bit has
placed "R" screw.
[0144] Additionally, at head (77) is the termination of helical
thread arrangement (79) at an open slot (77A) so that the entire
screw can be counter sunk into AAC. Finally, exterior of the shank
(72), from the head portion (77) to the opening, is pointed at one
end (78), and includes said large angled helical screw arrangement
(79) with wide threads. It will be seen that this is in sharp
contrast to the very shallow angle and narrowness of the helical
threads of a conventional screw. The design of thread of this
invention is unique to its application for maximum hold with least
negative torque influence thereon, and damage to the AAC. The
result of the invention is a screw which has all the advantages,
and more, of rebar but can be installed in one easy step directly
through numerous pieces of AAC and secures in place each piece of
AAC, regardless of where AAC is located, i.e., slope, angle, etc.
which before this invention was not possible.
[0145] Alternative fastening inventions are the hollow bar (FIG.
7AA) and flange bar (FIG. 7AAA). The hollow bar has a dust chamber
(74) within annular wall (72) with advantage of provided plural
cut-out windows having a scraper blades (76), which is a portion of
the cut-out of the wall extending tangentially from the annular
wall (72). In operation, the dust chambers (74) captures AAC dust
created by scraper (76), as well as through opening in pointed end
(78). The scrapers (76) serve two functions: 1) to enlarge hole
area around shaft (72) so that an air space is created between the
AAC and shaft (72), which space will be filled with mortar being
poured into gap around exterior of shaft at entrance to whole; and,
2) remove from the enlarged hole all lose AAC dust so that mortar
has a good surface for bonding. The design of thread of this
invention is unique to its application for maximum hold with least
negative torque influence thereon, and damage to the AAC and the
gaps (705) in thread are for purpose of allowing mortar poured into
opening created by flanges to flow continuously down between screw
wall and AAC and around threads sections. The result of the
invention is a screw which has all the advantages, and more, of "R"
screw, but can be manufactured for less cost and be custom cut at
site to variable lengths as thread gap (705) and opening pattern
repeats itself.
[0146] The crimping tool for cutting and forming hollow bar has
multiple blades which form functions of: 1) crimping tube which
helps hollow bar enter AAC and grind it, 2) cut it, and 3) form
teeth out of cut end for two functions: 3A) on end entering AAC,
teeth cut and grind up AAC (706) and feed AAC dust up into dust
chamber (74), and, 3B) end used for driving hollow bar into AAC
works as would a normal head on a screw would, as it designed to
receive a drill bit and teeth have gaps which can receive a
Phillips head screw driver bit and allow hollow bar to be counter
sunk.
[0147] The flange bar is similar to industry rebar except invention
is modified by unique flanges (701) which are positioned and angled
(705) to act like screw threads and design of being wider (704) and
thicker (703) at bar and then narrowing with receding leading edge
(704) and getting thinner towards end (703) provides service of
keeping bar centered in hole by resistance of flanges against wall
as it is inserted and as flanges bite into walls they bind
cementitious pieces together and prevent shifting and/or movement
while mortar is added around bar it sets up. It has advantages of
inexpensive to manufacture and length being custom cut from long
bar on site, but has disadvantage of it requiring pre drilling a
hole.
[0148] Another fastening device, the nail "N" screw (80), shown in
partial views in FIGS. 8-8D, has particular utility in securing
smaller items to a cementitious material, such as AAC. It can be
comprised of a strong, hard plastic instead of steel. It is unique
by its ability to be driven into the AAC with a hammer, while
further having the ability to be withdrawn by means of a rotational
hand tool, i.e., hand or powered screw driver (FIG. 8C). This
device overcomes problems of prior art in that it will not easily
work free over time and yet is removable using the correct tool
without damage the item to be secured and/or AAC. The fastener
member (80) hereof is comprised of a triangular threaded (82)
elongated shank (82), with very low number of revolutions around
shank and is pointed at one end (85). The pointed end has openings
(83) which aid the "N" screw to grip AAC by gathering and
compacting AAC dust which presses against AAC wall. The "N" screw
is topped at the opposite end by a head portion, where the head
portion includes prongs (84) for piercing AAC to provide additional
holding of the "N" screw in place. On the top side of head is a
slot (81) for removably receiving a screw driver head, as known in
the art, to remove the "N" screw from location. The design allows
for unique multiple applications in same location which no other
fastener with such simple construction provides in AAC.
Additionally, the elongated shank can be hollow (85) and a standard
finish nail (86) be driven through which explodes the tip (87) and
further anchors hammer nail. To remove the hammer nail, one first
applies a needle nose pliers to remove the finish set nail (86) and
then a screw driver and the screw's threads supply enough torque
for AAC wall to force exploded tip to re-close and remove "N" screw
from the AAC.
[0149] Turning now to tools,(FIGS. IIA-11E), a table version (FIG.
IIA) is of a block and panel architectural fabricator. The table
has router bits (110, 111, 112) with the potential for variable
positions, and ability for different bits (110, 112) on each router
cutting simultaneously so each side of block, panel and/or beam has
desired architectural features, including utility chase (111) as an
example in FIG. 11C, reference numerals 1, 4, 3, 6 and beams 30,
31, 32. FIG. 1ID is a partial view of a hand held version cutting a
casing block 3. The most unique aspect of the tools hereof is the
ability through combined use of the tools and template system of
FIG. 16 to fabricate finished openings for windows and doors in a
solid AAC wall.
[0150] A tool used for cutting utility chases into erected walls is
illustrated in FIG. 12, which is a partial top view of a hand held
utility chase cutter with the bit (120) which simultaneously cuts
notch for sheetrock (9) and chase (2). It uses the template guide
system hereof (FIG. 16) as does most of the hand held cutting
tools. FIG. (12) shows utility chase (2) with sheetrock (53)
installed using "N" screws (80), covering water supply (123) and
waste pipes (124). The utility chase cutter can be used for
vertical as well as horizontal runs. Since the bit protrudes beyond
the face of the interior wall, it is able to cut down behind the
base block and up behind the crown block. Then a standard drill can
cut holes for utilities through floor panel. The chase is covered
using a single cut to size a piece of sheetrock.
[0151] FIGS. 13 A-C are directed to cutting tools to implement the
processes of plunging 160 and guide templates 161, Circular saw
blade (130) may be used for cutting out chases (2) with less
difficulty and dust created by routing large amounts of AAC. Dual
bits (13 1), which may cut notches (9) for sheetrock, can work off
the same drive (FIG. 13B, 132) showing a circular saw blade (130).
The circular saw blade is simply fit into chase cutting tool, (FIG.
13C) and engages drive wheel (132). The blade harness (133) holds
it in desired position. All tools have special dust collecting
systems.
[0152] There is very limited waste product of AAC according to the
preferred practice of this invention, but what waste there is can
be easily taken care of by an AAC crusher (140), whereby crushers
(140) will transform all scrap pieces of the AAC (142) into a sand
like form (143), which is simply sewn into soil (144) like sand.
This unique process tool crushes waste cementitious pieces into
dust, so they do not have to be taken to landfills, which means
habitats manufactured by the instant invention can be constructed
with little or no waste AAC from the site having to go to a
landfill, thereby lessening construction costs and providing an
environmentally friendly practice.
[0153] As blocks of AAC are set in place, excess mortar can be
forced out beyond the wall face. To solve this problem FIG. 15
shows a partial perspective of present invention joint finisher
(150) The joint finisher has a unique roller (152) which serves
several useful function namely, keeps blade (151) at optimal angle
for removing excess AAC mortar from block face at joints and roller
smoothes out any residual trace amounts of mortar, and the spring
pressured cleaning blade (153) removes AAC which may accumulate on
the roller; so that now one movement replaces prior art's several
tools and motions.
[0154] FIG. 16 A & B are partial perspectives of the improved
processes for making openings in AAC, from simple utility openings
to openings for doors, windows and staircases. The template guide
system is comprised of several components: support arms (160) which
plunge, a standard size guide plate (161) which mandates a
strategically located template guide (162) to set a standard sized
distance from desired cutting as they interlock to provide straight
and dimensionally exact openings. A variation is template guide
(163) which is used for routing instead of cutting openings. An
example of the application is a finished window opening located on
wall. The present invention allows for finished completely
openings, including architectural routings while prior art's only
offered crude method for rough openings
[0155] Invention's process if for window opening to be measured and
located onto wall, then template guide (162) can be located 2"
wider around desired finished opening and fastened, preferably
using "N" screws (80). The guide plate (161) interlocks with
template guide (162, 163) and the tool is simply plunged straight
via support arms (160) into AAC. FIG. 16 shows two tools, a roto
zip type device (FIG. 16A) and reciprocating saw (FIG. 16B), while
other tools are possible. All tools require original bits/blades
(165), etc. which are longer and stronger than prior art as
presently no one manufactures blades and bits which are long enough
to plunge, nor strong enough not to bend or warp in use so that
dimensionally accurate openings are created.
[0156] The hand held finishing tool shown (Figure 11D) and may be
used with the same template guides (162, 163) so that an
architecturally finished opening results where there was once just
a wall. The window is simply slipped in and caulked and/or finish
nailed. No additional wood trim or casing is required. The outlet
and switch openings, beam notches, etc. require a different type of
template guide (163) which uses prongs (164). The guiding arms are
kept perpendicular by level bubble on support arm (160). In
difficult positions, such as a comer notch, an angled template
guide (166) is used and, as the roto zip type tool goes around a
guide, a chunk of AAC is removed which allows the beam to seat into
wall and be finished with mortar and "R" screw.
[0157] For easing electrician's job of installing electrical wire
(FIG. 17A) into utility channel , the wire inserting tool (170) has
a long, specifically angled bar (170) with ability to slip into
utility channel (202) and wheel (175) enables installer to simply
walk along while the wire feeding wheel (171) by design aligns and
lifts wire onto roof of channel where staple fastener (172) shoots
a unique staple (174) which does not easily pull out around wire
and into AAC.
[0158] Invention's internal air duct system (FIG. 18, 180) can be
housed in top beam and inside structural beam system. A PVC type
pipe can be manufactured within cementitious material (AAC) and
therefore benefits AAC by reducing its weight and simultaneously
reinforcing it, and AAC benefits air duct by insulating it, hiding
duct system and enabling easy access for vents (181). The vents
(181) can have various sizes for openings as engineered for
facilitating desired air flow. Where top beams and support beams
intersect each other (FIG. 18B, 182), cuts are made appropriately
and directional inserts (183 A, B, C,) employed so that result is a
continuous air flow system (FIG. 18C) regulated by vent opening
size and proximity to air return vents. System can be located a
centralized location and initial service ducts run through a chase
shared by other main utilities and then hooked up to internal duct
system.
[0159] It is recognized that changes, variations and modifications
may be made to the method of this invention, and to the securing
device, particularly by those skilled in the art, without departing
from the spirit and scope thereof Accordingly, no limitation is
intended to be imposed thereon except as set forth in the
accompanying claims.
* * * * *