U.S. patent application number 11/061296 was filed with the patent office on 2005-09-29 for trilithic and/or twin shell dome type structures and method of making same.
Invention is credited to DeFever, Michael D., DeFever, Ryan Michael.
Application Number | 20050210767 11/061296 |
Document ID | / |
Family ID | 34988069 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050210767 |
Kind Code |
A1 |
DeFever, Michael D. ; et
al. |
September 29, 2005 |
Trilithic and/or twin shell dome type structures and method of
making same
Abstract
Trilithic Shell, Twin Shell, Multiple Shell, Curvilinear Shell
as well as Free-formed Structures described herein each employ an
inflatable membrane having a peripheral edge secured to an outer
foundation base. An ultra-light membrane (air-form) having a
network of internal cross connecting restraints is additionally
secured to the inner foundation base to permit a novel and unique
curvilinear surface. Pressurization then creates the backdrop upon
which various urethane layers are applied which when laced with
rigidifying tubes become the defining backdrop beneath which
numerous cross connecting braces which when snapped into position
effectively lock an inner framework to an outer framework thereby
producing a self supporting truss like structure both compatible
with either current dome construction and/or conventional
construction practices. Shotcrete being then sprayed from the
interior over said urethane coated backdrop forms highs at
framework intersections and natural lows in between followed by the
insertion of inflated cell tubes which span the created network of
horizontal and vertical cavities are next over sprayed with
urethane foam necessary to form the next natural backdrop over
which two or more shotcrete/steel reinforced separate yet cross
connected planes may be achieved. Such multiple yet independent
rigid layers now having thousands of inner-connecting cross braces
through which interior voids become natural chase-ways effectively
displace 50% or more of what might otherwise be solid concrete as
would be the case with all prior art thin shell structures and/or
conventional stem wall construction practices. Such Free Formed
curve-linear structures effectively reduce material and labor costs
by as much as 50%, eliminate snap-through or oil-can buckling
tendencies, enhance overall structural capacity, eliminate all
height to diameter restraints, permit larger structures, facilitate
floor suspension and attachment, and allow mechanical, electrical
and HVAC distribution through interior chase-ways which cannot be
achieved with prior art concrete thin shell single thickness
structures and/or conventional stem wall, construction practices to
date.
Inventors: |
DeFever, Michael D.;
(Waukesha, WI) ; DeFever, Ryan Michael; (Bonduel,
WI) |
Correspondence
Address: |
MICHAEL D. DEFEVER
2014 S. EAST AVE. #11
PO BOX 2006
WAUKESHA
WI
53189
US
|
Family ID: |
34988069 |
Appl. No.: |
11/061296 |
Filed: |
February 18, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60546358 |
Feb 21, 2004 |
|
|
|
Current U.S.
Class: |
52/80.1 |
Current CPC
Class: |
E04B 2001/3264 20130101;
E04B 1/169 20130101; E04B 1/3511 20130101 |
Class at
Publication: |
052/080.1 |
International
Class: |
E04B 001/32 |
Claims
1. A method of constructing a freeform structure comprising, the
steps of constructing a light weight air-form by incorporating sewn
in sleeves into which tubular reinforcements are inserted and bound
to said sleeve by a resinous material thereby creating an internal
network system through which restraining lines are passed so as to
achieve an air-form weighing several time less then previous art
air-forms while securing peripheral edge of said air-form to the
outside base foundation, while additionally securing internal
restraining lines to the inside base foundation so that while under
pressure outward expansion of the air-form is restricted by said
internal network system being placed in longitudinal as well as and
latitudinal tension, thereby forming subsequent layers of insulated
foam material on an inner surface of the inflated form, securing a
reinforcing mesh to an inner surface of said foam layer,
temporarily attaching a second horizontal rebar, attaching cross
connecting braces (USIS Braces) to said reinforcing mesh,
un-attaching said second horizontal rebar and locking said
horizontal into the USIS Receiver Socket, followed by inner
vertical rebar placements to produce a second layer of said
reinforcement mesh or multiple layers necessary to create steel
framed cavities or voids separating said independent multiple (two
or more) layers of steel reinforcement, applying one or more layers
of a cementitious material to the "outermost" inner mesh framework
against the backdrop of urethane foam to a depth sufficient to
embed said reinforcing mesh while building thickness at
intersections where horizontal, vertical and cross bracing rebar
connect, inserting un-inflated cell tubes between said created
steel framed cavities, inflating said cell tubes, filling space
external said cell tubes and within the created vertical channels
formed into the outer shotcrete shell with a lightweight urethane
or other material to displace what would normally be concrete
thereby displacing weight and creating a second flat backdrop
surface or multiple flat backdrop surfaces to which again one or
more layers of a cementitious material are to be applied to a depth
sufficient to embed said reinforcing mesh whereby achieving a
multiple shell like structure.
2. A method as defined in claim 1 including the steps of securing a
plurality of tension lines thereby creating an internal network
system to restrain and stabilize an air-form in preparation for
urethane foam layers and/or similar applications, said internal
network system having 4 way intersections to which tubes are
connected to create patterns through which tension lines extend and
secure to base thereby strengthening the air-form necessary to
apply a resin coating an underlying urethane foam application
thereby resulting in a more durable foam shell requiring less
interior air pressure.
3. A method as defined in claim 2 wherein each of said hanger
members having an extended length over the conventional length to
include a larger base portion then the conventional size hangers,
while disposed against said 1.sup.st foam layer, to including an
improved method over the conventional practices by applying a
second layer of insulation being colored to assist in achieving
more uniform thickness application thereby resulting in more
uniform suspension of imbedded hangers within said foam material
while eliminating possible air pressure penetration to the exterior
to cause a distortion free exterior surface.
4. A method as defined in claim 1 wherein said air-form consisting
of an internal network of restraints comprised of sewn in fabric
sleeves, imbedded tubes, inserted tension lines, internal resin
coating having a cooperative relation with said inflatable form so
as to permit inflation to a lesser degree and without either an
external restraints or internal caged ribs.
5. A method as defined in claim 1 & 4 wherein internal
restraints permit the air-form to be constructed lighter and
therefore inflated to a lesser pressure then conventionally
practiced methods thereby eliminating the need for external
restraints resulting in minimal curvature or arching between the
internal framed supports, eliminating external wire restraints that
require an exterior finish coating, whereby eliminating snap
through buckling and/or oil can buckling as the two separated
shells are constructed independently, are cross braced, become self
supporting, and provide several times the conventional load bearing
strength per square foot of surface area.
6. A method as defined in claim 1 wherein said cross bracing
consisting of individually snapped into place Universal Snap In
Standard (USIS Braces) thereby connecting an outer shell or layer
with a separated inner shell or layer by way of several hundred or
as many as several thousand steel bars and/or other composite
material bars which together form a truss like connection between
two or more spherical, half spherical, barrel, half barrel, oval,
elliptical, cylindrical, flat wall and/or free formed surfaces
thereby producing structural load capacities several times greater
then conventional dome shell practices, hence the designation Twin
Shell Structure, Multiple Shell Structure, Trilithic Dome Shell
and/or free formed curve-linear structures most appropriately
define this new technology.
7. A method as defined in claim 1 whereby cavities are created
between shells and more specifically between USIS Braces which
connect two or more shell surfaces thereby allowing un-inflated
ribbons of polyethylene film or similar displacement type material
to extend from one point to another point in either a vertical,
horizontal and/or laterally in direction whereupon the space
between such extended inflated voids through which said cross
bracing extends, and once filled with a light weight insulation
such as urethane or similar polymer and/or lightweight cementitious
mixture resulting in the displacement of concrete weight yields a
structural truss relationship between said multiple shells thereby
providing structural capacities several times greater then
conventional dome structure presently provide and/or hope to
provide.
8. A method as defined in claim 1, claim 6 and claim 7 wherein said
USIS Brace is constructed in a manner that may structurally connect
an outer separated concrete shell like form to an inner separated
concrete shell like form while simply snapping into position and
thereby retaining both vertical and horizontal adjustability to
include the capacity to receive an inserted interlocking
circumferential rebar which when connected to its vertical
interface forms a self supporting framework and perfectly aligned
cavities through which inflated cell tubes may extend to create
eventual chase-ways.
9. A method as defined in claim 1 and claim 8 wherein inserted cell
tubes constructed of polyethylene film or similar type plastic in
various diameter sizes are manufactured by method of heat sealing
or joining both ends whereby one end receives an inserted inflator
tube that can be simply cauterized once the desired pressure is
achieved, whereby such tube is used to define both the size and
upward curvature of what is to become a chase-way by method of
being installed between an outer shell surface of concrete and an
inner shell framework of steel rebar and separated by numerous rows
of cross connecting USIS Braces which traverse back and forth to
connect an outer shell to what will become an inner shell once the
void separating one cell tube to the next is filled with a
displacement material such as urethane foam and or light weight
concrete as a method to displace weight and to effectively achieve
a second flat surface to which a second application of shotcrete is
to be applied to render an inner shell surface.
10. A method as defined in claim 1 wherein said air-form has a
generally circular periphery secured to said base, said form being
configured to establish a dome shape when inflated and restrained
by internal network system comprised of sewn seams, stitched
sleeves, inserted tubes, which when restrained by a plurality of
tension lines extending generally radially from the base foundation
along the underside of the said air-form through said tubes
imbedded in said sleeves to an apex coupler thereby connecting to a
spring-loaded-tension device and then back down through said tubes
imbedded in said sleeves along the underside of said the air-form
to connect to the opposite side base foundation, and a plurality of
second tensions lines extending substantially circumferentially of
the dome shape generally concentric with the apex thereof, said
first and second tension lines being in generally transverse
overlapping relation and merely overlapping a connectivity is a
function of the 4 way interconnect that receive both horizontal and
vertical tube placements which comprise the internal network which
underlies designated seams to form defined pattern of support.
11. A method as defined in claim 1 including the step of
interconnecting said internal network as defined in claim 10
thereby reducing the conventional air pressure thus permitting a
lighter weight air-form to be used whereby permitting larger spans
to be without use of an exterior restraining cable system or
internal caged beam supports whereby a larger urethane shell may be
applied to a lighter air-form thereby permitting a greater amount
of initial rebar to be suspended until such time as the self
supporting framework as defined in claim 8 can be assembled,
wherein the application of steel and shotcrete are not a function
of what the air-form can support rather what the self supporting
frame and the initial outer most layer of shotcrete can support
until the cell tubes as defined in claim 7 are placed thereby
permitting a second-application of shotcrete to an inner shell
thereby providing a structural" capacity several times greater then
all other conventional methods allow while effectively eliminating
any difficulty associated with snap through buckling and/or oil can
buckling, while additionally diminishing the conventional and
prevailing height to diameter restrains at the same time.
12. A method of laser projecting not only all critical placements
within a dome structure but also locating and implanting attachment
points throughout interior surface, strategically placing both
truss receivers from which drop rods are suspended, metal ground
plates to which floors are to be quickly attached, as well as all
window and door openings which must be defined before any work may
commence.
13. A method of constructing light weight truss frames assemblies
that can be made at ground level and levitated into position once
the layout work has been completed in accordance with claim 12.
14. A method of levitating assembled truss frames as defined in
claim 1 and 13, thereby elevating said frames to a desired floor
height as defined in claim 13 whereby DC high torque motors are
used to revolve a gear reduction process comprised of a specially
designed Truss Pin that is engineered to climb welded together
segments of structural Acme Drop Rods extending from the ground
level of the dome to a designated elevation or height at which time
such truss members and their associated attachment flanges,
bearings, and ground plates meet and are thereafter secured as
defined in claim 1.
15. A method of constructing a dome building comprising the steps
of securing a peripheral edge of an inflatable form to a external
base, securing an internal restraining network to the internal base
foundation, inflating said light weight air-form under low pressure
into a dome shape so that outward expansion of the form is
restricted by said restraining members, applying a application of
resinous material to the combined sleeves, ribs, and tubing to
comprise a unified network of restraint, forming a first layer of
insulation foam material on an inner surface of the inflated form,
applying hanger brackets having longer and softer wire by means of
laser placement device, securing a reinforcing mesh to an inner
surface of said foam layer, using laser locating devices to place
drop rod receiver, window and door locations, floor locations,
ground plate locations, skylight locations, applying a second and
third or more layers of light weight urethane or similar copolymer,
placing horizontal outer rebar in a circumferential manner, placing
vertical outer rebar to strategically positioned hanger brackets
through use of laser spotting, placing cross connecting SIS Braces
to secure outer shell to a second or third inner shell, placing
internal horizontal rebar temporarily, placing internal vertical
rebar to USIS Brace and Horizontal rebar using one common wire
attachment, placement of cellular foam caps over internal
intersections, spraying outer layers of shotcrete through all
layers of rebar, placement of cell tubes within crated voids,
application of urethane foam between cell tubes, applications of
shotcrete to the second interior shell backdrop, of FIG. 6
16. A dome structure made in accordance with the method of claim
15.
Description
BACKGROUND OF THE INVENTION
[0001] Present invention relates to conventional stem wall
construction practices, roof shell construction practices, tunnel
construction, and more specifically to concrete dome shell
structures which are most commonly referred to as Thin Shell
structures within in the industry.
[0002] Such structures to date typically have been constructed
utilizing numerous and/or various construction methods whereby a
single shell thickness of concrete is achieved. Essentially,
varying methods of layering dissimilar materials necessary to
define the outer dimension of such structures and in particular
dome structures have been used for decades by spraying concrete for
example to either the inside and/or outside of a form.
[0003] Structures for example being typically constructed by
inflating an air-form, followed by applying an insulating urethane
foam material to the interior of said air-form, followed by
securing a reinforcing mesh and/or rebar to said urethane foam
layer, followed by one or more layers of a cementitious material
being applied to effectively embed the reinforcing mesh into one
thickness, are current methods generally known in the industry.
[0004] Numerous Thin Shell dome structures for example are in use
today, however, their radius of curvature limitations (height of
the dome shell having to be at least 35% of the diameter) has
severely restrained their overall use and acceptance by architects,
contractors and the general buying public. Secondly, while Thin
Shell structures have utilized varied amounts of rebar and creative
configurations for both vertical and horizontal rebar placements in
order to achieve spans of up to approximately 300 feet in diameter,
said Thin Shell structures are still no match for conventional
construction methods due to numerous unresolved limitations that
still have not been remedied. For Example: Load capacities have
been typically adjusted by either, increasing the quantity of
imbedded steel rebar, enlarging the diameter of said steel rebar,
decreasing the space between said steel rebar placements, and/or
gradually increasing the overall concrete single shell thickness
that contains said steel rebar reinforcements until the shell can
no longer support itself. However, through all of the Thin Shell
modifications over the past decades, nobody has to date proposed
the use of two or more separated yet parallel interlocking dome
shells thereby achieving a truss like condition as a means of
obtaining greater structural strength. Moreover, all attempts to
conquer curvature restraints and size limitations for larger domes
structures by South and/or all others referenced in South's
Background of the invention, U.S. Pat. No. 5,918,438 issued on Jul.
6, 1999 have proved futile as evidenced by the fact that no dome
structures larger than 300' in DIA have been yet constructed. More
specifically, all attempts to increase a Thin Shell's diameter size
and/or the Thin Shell's inherent strength have been limited to
manipulating long standing methods of constructing a single
thickness Thin Shell structure be it either adding various types of
structural support above and/or below a single thickness thin shell
dome like structure, while conventional construction practices
likewise rely on increasing wall thickness just as roofing truss
systems grow in size and weight to support larger structures.
[0005] In pursuit of building beyond 300 or 400 feet in diameter
U.S. Pat. No. 5,918,438 issued to South on Jul. 6, 1999 discloses
that: "a concept of caged steel and concrete beams being fashioned
below a single thin shell as a more particular method of making
larger dome structures to be feasible". In reality, however the
caged beams necessary to support such a single thickness dome like
structure would themselves weigh several times the weight of the
thin shell they are designed to support, while the same dramatic
escalation of weight also impedes larger conventional construction
by increasing both material and labor in the same manner.
[0006] South's prior art U.S. Pat. No. 4,324,074 issued Apr., 13,
1882 likewise could not accommodate structures larger then 300' in
diameter, while additionally being restrained by the 35% height to
diameter limitations. It is therefore significant to note that no
300' to 400' or larger DIA domes, nor any other structure having
heights less then 35% of their diameters have been built to
date.
[0007] In U.S. Pat. No. 5,918,438 under BACKGROUND OF THE INVENTION
page 1, South incorporates by references both U.S. Pat. Nos.
3,277,219 and 4,155,967 which were the previous prior art toward
also increasing the diameter and strength of dome-like structures
by adding steel reinforcement to a single thickness of concrete to
achieve what in the industry is termed a (thin shell) structure.
Therein South discloses on page 1. paragraph 2, that: "in many
applications, such structures provided significant economic
advantages over conventional building practices that typically
utilize lumber, bricks, concrete blocks and the like to implement
conventional rectangular or other generally square corner
structural configurations". Mr. South then continues: "The economic
advantages of buildings constructed with inflatable forms having
insulation foam and concrete layers applied to their inner surfaces
are derived in part from the relatively short period of time
required to construct such buildings as compared with conventional
building techniques". South, however, avoids mentioning that to
implement his new art as disclosed in U.S. Pat. No. 5,918,438,
issued on Jul. 6, 1999 both materials and labor associated with his
new art will be viewed as prohibitive as compared to all other
conventional art. South then continues to disclose: "In general,
such dome type building structures are made by securing the
periphery of the inflatable form to a footing or foundation,
inflating the form, applying an insulating foam layer against the
interior surface of the inflated form, attaching a relatively rigid
reinforcing grid or mesh to the interior surface of the cured foam
layer, and thereafter applying one or more cementitious layers, as
by spraying shotcrete to the foam layer so as to embed the
reinforcing mesh and/or rebar whereby providing a self-supporting
shell-like dome structure" which implies that the actual
application of shotcrete is quite essential to obtaining self
support. South goes on to further clarify in his background of the
invention page 1, paragraph 3: "Dome shaped building structures of
the aforementioned type have proven to be structurally sound and
particularly environmentally compatible due to their relatively
high thermal efficiency". South then discloses further in his
second sentence of page 1 paragraph 3, that: "One drawback to these
known dome structures is that they are restrictive in size. As the
inflatable air-form is made larger to produce a larger diameter
dome, such as a diameter exceeding 300-400 feet, the higher air
pressure required to inflate and raise the heavier form may cause
the form to tear. In addition if the wall thickness of a large size
dome shells were made sufficiently thick to theoretically provide
the necessary strength for self-support, the weight of the
additional concrete may well exceed its increased strength so that
inward buckling occurs, generally termed "snap through" or "oil
can" buckling".
[0008] South suggests in U.S. Pat. No. 5,918,438 that developing a
restraining cable system and the resulting concept of constructing
underlying caged beams of steel and concrete under the "Thin Shell"
to be a "far better method and/or improvement over all previous
attempts made to overcome the limitations of such dome-type
buildings" which use such as, but not limited to, rigid skeletal
frameworks of struts or tubular members to define the contour of
the desired shell as disclosed in U.S. Pat. No. 5,408,793 by way of
reference to U.S. Pat. No. 4,442, 059, wherein it is disclosed
that: "struts or tubular members being secured together at
intersections by clamps with the lower struts fixed to a base or
foundation. An air-impervious membrane envelope is provided within
the framework and is inflated to place the struts or tubular
members in tension. A coating, such as a fiber-reinforced resin or
cement, is applied to the outside surface of the membrane to cover
both the membrane and framework. After the desired coating
thickness is allowed to set, the air pressure is released and the
membrane removed, whereupon, the struts or tubular members return
to a non-tensioned state and detach from the exterior coating
material on the membrane. The inner surface of the construction may
then be sprayed with resin to cover at least the strut connecting
clamps".
[0009] Furthermore, U.S. Pat. No. 5,408,793 discloses that: "a dome
structure wherein a membrane is inflated to a desired dome shape
against radial members made of steel wire, wire rope or glass or
carbon fibers and having their bottom ends secured to a base on
which the dome is built. The interior and exterior surfaces of the
inflated membrane are coated with a rigidifying material such as
shotcrete which hardens to form a structural composite layer with
the membrane and radial wires embedded in the rigid composite
layer. Circumferential high-tensile tensioning elements may be
applied around the structure internally of the composite layer to
counteract outwardly directed bursting forces created by materials
contained within the finished dome". The above disclosures clearly
demonstrate that the general approach and focus again has been
toward strengthening the single thickness "thin shell" structure in
order to span larger diameters.
[0010] U.S. Pat. No. 5,918,438, also discloses that: "while dome
structures of the type disclosed in U.S. Pat. Nos. 4,442,059 and
5,408,793 has enabled domes of larger size to be constructed, they
have not altogether eliminated the problem of snap-through or oil
can buckling as very large domes, such as domes having base
diameters significantly greater than 300 feet, are constructed.
Such domes South states "have the further disadvantage that they
are relatively complex and expensive to make, as compared to a dome
structure as disclosed in U.S. Pat. No. 4,155,967 which cannot be
constructed in excess of 300' in diameter". South, however, does
not emphasize that his U.S. Pat. No. 5,918,438 having both an
exterior cables system as well as its massive interior caged ribs
system must be first free hand assembled externally, then free hand
assembled internally before carefully and artistically spraying
literally dozens of successive layers of shotcrete to achieve a
dimensionally consistent beam width, one rib at a time--layer upon
layer, which is logically more complicated, more time consuming and
certainly much more demanding labor wise then any prior art he
references to therein, be it U.S. Pat. Nos. 4,442,059, 5,408,793,
and/or 4,155, 967. Moreover it just may be the precise reason why
such a caged beam structure still has not been constructed to
date.
[0011] Thus, a dome structure of the type to be later disclosed
herein, which can be constructed to accommodate diameters
approaching 1000 feet in diameter, is the result of a complete
redesign of all aspects of the dome construction process. By
foregoing the heavier air-form, eliminating exterior restraining
cables, eliminating massive concrete and steel internal ribs and
dispensing with the concept of gradually thickening a single
thickness dome shell in lieu of a Multiple Shell Type structure,
herein after referred to as (MST) structure, a truss like assembly
is realized whereby a structural rebar framework becomes
essentially self supporting, load capacities increase several times
over and the combined concrete/steel weight per sq./ft of surface
area diminishes appreciably for either conventional and/or dome
type structures. Said "MST structures resolve not only the overall
diameter limitations, the previously mentioned height not to
exceed: 35% of the diameter limitations, but also the "snap through
buckling and/or "oil can buckling drawbacks thereby. permitting
numerous other novel concepts and methods of construction to be
additionally implemented since structures may now provide the load
carrying capacity necessary to support such measures. For Example:
Efficient floor truss assembly methods, advanced bearing point
suspension systems, floor truss levitation and attachment methods,
skylight placement methods, stair well suspension concepts,
partition wall placement methods, mechanical, electrical and HVAC
distribution methods, and "wind driven natural ventilation methods"
that effectively harness the thermal mass energy stored within the
MST structure can now be easily employed. Therefore the above
technologies would provide a substantial advancement over any of
the current dome building art forms as either disclosed in either
U.S. Pat. Nos. 5,918,438, 4,442,059, 4,155,967 or 5,408,793.
SUMMARY OF THE INVENTION
[0012] A general object of the present invention is to provide a
novel free-formed curve-linear roof like structure, tunnel
structure MST dome like structure and/or free formed space over
incorporating multiple shell layers and method of making same that
enables a substantially larger size shell-like dome structure to be
constructed then heretofore obtainable.
[0013] A more particular object of the present invention is the
following method of constructing multiple combinations of separated
yet interconnected shell layers, whereby the resulting structures
load bearing strength, overall diameter size, height to diameter
restraints, floor suspension limitations, skylight opening
limitations, as well as the resulting efficient distribution of
mechanicals such as but not limited to electrical plumbing and HVAC
become significantly improved then heretofore obtainable, by use of
the following:
[0014] a. A novel light weight inflatable yet high strength
air-form membrane having equal distant sections that are double
reinforced and sleeved intermittently to accept an internal tubular
grid assembly through which tension lines are drawn so as to
provide larger diameter spans without tearing then heretofore
obtainable.
[0015] b. A novel concept of interconnected cross bracing herein
defined as Universal Snap In Standards (USIS Braces) that results
in either a free standing "twin shell" dome like 'structure,
"multiple shell" or "Trilithic shell" shell like structure, thereby
providing far superior load bearing strengths then heretofore
obtainable.
[0016] c. The novel insertion of inflated cell tubes thereby
creating voids for the exact purpose of eliminating concrete volume
whereby significant weight displacement is achieved, thereby
causing structural strengths to escalate dramatically, also proves
to be a substantial advancement over previous art then heretofore
obtainable.
[0017] Accordingly, several other objects and advantages of the
novel multiple shell innovation which results in improved
structural strength and the reduction of height to diameter
restraints present themselves and are therefore included because
they have not been heretofore obtainable and they are:
[0018] a. A novel system for suspending numerous floors or levels
may be now employed due to this highly strengthened interconnected
multiple shell structure then heretofore obtainable.
[0019] b. A novel method of levitating floors constructed at ground
level up and into position and thereafter quickly connecting said
floors to the multiple shell structure in an efficient manner due
to the improved structural capacities and weight transference
abilities associated using multiple shell assemblies as disclosed
herein, then heretofore obtainable.
[0020] c. A novel method of distributing electrical, plumbing and
HVAC throughout the multiple shell structure may now result at any
time after the concrete shell is completed as cell tube voids
within the dome (between shell layers) serve as vertical chase-ways
permitting more efficient placement of mechanicals then heretofore
obtainable.
[0021] d. A novel method of utilizing natural external wind
pressure to cause internal air circulation within the Multiple
Shell structure thereby harnessing millions of BTU's of thermal
energy stored within the mass of the MTS structure then heretofore
obtainable.
[0022] Briefly: In constructing such a superior strength multiple
shell structure the peripheral edge of a new lightweight air-form
typically weighing several times less then conventional air-forms
is secured to the base or foundation over which the multiple shells
is to be constructed. The lightweight air-form while incorporating
slightly oversized stitched tubes or sleeves at designated seams
produces an equal distant pattern of support. Once the lightweight
air-form is inflated, rigid thin wall urethane or type similar
tubes are inserted into said stitched sleeves thereby producing a
cross pattern of support after which the insertion of vertical
tension lines being first secured to the base foundation while
secondly horizontal tension lines are circumferentially strung
whereby the combined effect is to both limit and restrain movement
of the air-form during the construction process. Thereafter, and
upon slightly increasing the air-form interior pressure whereby
creating a slight but noticeable exterior cross pattern to emerge
on the outer shell, a urethane elastomeric penetrating resin is
applied from the inside to both adhere and bind sleeves, seams and
inserted urethane tubing together. Once fully cured the lightweight
air-form becomes even more stabilized and strengthened after which
the first of three additional urethane foam applications in color
coded layers are applied successively which insures a more uniform
thickness application while permitting one to more easily
distinguish between one application and the next.
[0023] Thereafter the installation of internal horizontal and
vertical rebar as generally known and disclosed in U.S. Pat. Nos.
3,277,219 and 4,155,967 are incorporated while the lengths of such
previously disclosed hanger brackets are extended substantially in
accordance with the herein defined novel method of both attaching
and aligning said rebar in both a more expedient and efficient
manner then heretofore been obtainable
[0024] Once the outer horizontal and vertical rebar framework has
been attached by way of such lengthened hanger brackets the
strategic application of Universal Snap In Standards (USIS Braces)
serve to create the unique cavity or separation between the outer
rebar reinforcement framework and an inner reinforcement framework.
Once the inner-most horizontal rebar is snapped into the USIS brace
receiver, the inner vertical rebar can be quickly attached thereby
causing a multiple shell framework that is virtually self
supporting. Shotcrete being then sprayed through the inner
framework builds surface thickness over the outer framework and
against the light weight and strengthened air-form which has become
essentially a backdrop upon which shotcrete is applied, while
specific attention is given to applying more shotcrete thickness at
intersecting points where the USIS Braces connect to both vertical
and horizontal rebar thus reinforcing all such attachment points to
the outer shell framework. The resulting appearance will be that of
highs and lows in vertical rows around the perimeter of the
multiple shell structure. Thereafter flat (un-inflated) cell tube
(ribbons of polyethylene film) will be next drawn from the floor
upward and between the created rectangular cavities on toward the
apex of the structure. After inflation of said cell tubes the voids
separating each inflated cylinder will be sprayed with either
lightweight 1.5 lb density urethane foam and/or lightweight
shotcrete consisting of cement and Styrofoam and less aggregate
depending on intended use of said cell tube void. The inner
resulting surface once leveled over with urethane foam will appear
just as the outer application of urethane foam appeared before the
first coating of shotcrete was applied. This new second surface
will then receive a second inner thickness of 6,000 PSI shotcrete
thereby creating the inner wall of the inner shell portion of a
Multiple Shell Type structure.
[0025] Further features and advantages of the present invention
will become apparent from the following detailed description of the
invention taken with the accompanying drawings wherein like
reference numbers designate like elements throughout the several
views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective left side frontal view of a 400' DIA
approximate size Multiple Dome Shell type structure that may be
constructed in accordance with one embodiment of the present
invention;
[0027] FIG. 2 is a representative fragmentary vertical sectional
view from the peripheral foundation through to the apex of a Twin
Shell and/or as may be defined a Multiple Shell Type Structures of
FIG. 1.
[0028] FIG. 3 is a perspective view through a Floor Truss/Cross
Member intersection of FIG. 2 in accordance with one embodiment by
which Vertical Drop Rods connect to floors which are suspended from
the Multiple Shell Type structure.
[0029] FIG. 4 is a more detailed fragmentary vertical perspective
view taken through the wall of the dome shell of FIG. 2 and is
representative of the manner in which all component materials such
as but not limited to: Universal Snap In Standards or (USIS
Braces), Cell Tubes (inflated polyethylene cylinders or voids),
Urethane Foam Layers, Horizontal and Vertical Rebar, Hanger
Brackets, Reinforcement Rebar, High Strength Shotcrete,
pre-positioned Knock Out Plugs, pre-positioned Tension Tubes, and
Restraining Cables are all systematically assembled to efficiently
construct a Multiple Shell Like structure using far less labor.
[0030] FIG. 5 is a fragmentary vertical sectional view illustrating
the manner in which connecting rows of "universal snap in standard"
(USIS Brace) attach to vertical re-bars, which are connected to
horizontal re-bars which extend circumferentially around the
perimeter of the outer shell of the structure of FIG. 2. FIG. 2
represents only one embodiment consisting of two shells (outer and
inner) being interconnected together, however, three or more
(multiple shells) may be also fashioned in the same manner whereby
achieving even greater structural capacity as would be required
with domes approaching 1000 feet in diameter.
[0031] FIG. 6 is a fragmentary vertical sectional view illustrating
the manner in which vertically placed rows of "cell tubes"
(inflated polyethylene tubes or voids) are positioned equal distant
between the outer and inner shell frameworks of steel re-bar and
likewise positioned equal distant between the inserted rows of USIS
Braces of FIG. 5.
[0032] FIG. 7 is a representative fragmentary vertical sectional
view near the apex of the dome shell showing a "drop rod receiver"
implanted and secured back by way of rebar to both the outer and
inner walls of FIG. 2.
[0033] FIG. 8 is a fragmentary vertical sectional view, on an
enlarged scale, through the wall of FIG. 2 which is representative
in accordance with one embodiment of the manner in which Truss
Beams connect to both the inner and outer walls of a Twin Shell
and/or Multiple Shell Type Structure of FIG. 2.
[0034] FIG. 9 is a perspective view, on an enlarged scale, through
a connecting floor truss and its cross member truss of FIG. 2 which
is representative in accordance with one embodiment of the manner
of which Truss Braces" support Floor Truss intersections and
thereby effectively suspending such floor systems from a Twin Shell
and/or Multiple Shell structure.
[0035] FIG. 10 is a perspective view on an enlarged scale of the
interior side of the inflated air-form once both vertical and
horizontal tension tubes have been inserted through the sewn in
sleeves, joined with 4 way cross connects, over-sprayed with
penetrating resin, restrained by tension lines and made ready for
the first application of urethane foam.
[0036] FIG. 11 is a perspective drawing further defining FIG. 10,
wherein, Stanchion Cups, Rebar Hold-down Cinches and Cable Crimps
are employed to restrain and stabilize the air-form, while
elastomeric penetrating resin bonds said components together
[0037] FIG. 12 is a perspective view illustrating in accordance
with one embodiment a technique for the "inner cross connection of
horizontal and vertical sleeved seams associated with the air-form
membrane tension lines".
[0038] FIG. 13 is a fragmentary vertical sectional view
illustrating in accordance with one embodiment a technique for
"circumferentially cross-connecting vertical tension lines over
horizontal tension lines of FIG. 12. The lower of the two drawings
defines the membrane folds and method of assembly to include a
locking stitch pattern which permits the internal sleeve to
uniformly run parallel to all seams.
[0039] FIG. 14 is a perspective view, to illustrate the manner of
connecting a plurality of internal tension lines at the apex of a
given dome shell thereby limiting and/ or restraining the air-form
from outward pressure and/or movement during either a Twin Shell
and/or Multiple Shell construction process;.
[0040] FIG. 15 is a top view of the truss frame intersection in
accordance with one embodiment of the present invention. This view
shows the typical placement of a reduction motor at a Drop Rod
Intersection for purposes of lifting an entire floor from numerous
Drop Rod locations simultaneously when synchronized with all other
such lifting points.
[0041] FIG. 16 is a fragmentary sectional view, on an enlarged
scale, through a connecting floor truss and its cross member truss
of FIG. 3 which is representative in accordance with one embodiment
of the manner of which floor systems are constructed at ground
level on strategically positioned Assembly Standards which thereby
insure that all floors are dimensionally constructed exactly the
same making installation simple.
[0042] FIG. 17 is a perspective drawing of the Universal Snap In
Standard Brace Snap Clip (USIS Brace Snap Clip) of FIG. 5 to
include the new method of connecting USIS Braces to horizontal and
vertical rebar assemblies associated with either, Twin Shell
Structures, Multiple Shell structures, Trilithic Structures,
Free-formed Curve-linear Structures, Tunnel Structures,
Conventional Roof Over Structures and/or Curve-linear Space Over
structures.
[0043] FIG. 18 is a fragmentary transverse sectional view, on an
enlarged scale of an interconnecting 4 way intersection through
which, horizontal and vertical tension lines extend.
[0044] FIG. 19 is a fragmentary sectional view of a laser pointing
device that permits the exact layout of all truss rod receivers
when placed perfectly level on top of the strategically situated
Assembly Standards. Accordingly the construction of all floors
within any Twin Shell and/or Multiple Dome Shell structure can be
precisely duplicated using these two simple devices in conjunction
with one another.
[0045] FIG. 20 is a perspective drawing showing the sealed end of a
Cell Tube protruding from a dispensing carton thereby depicting a
method by which they may be drawn up and through rebar cavities
with the use of a simple line cord just prior to actual tube
inflation.
[0046] FIG. 21 is a perspective drawing of the Cellular Poly-Foam
Caps which may be snapped over all inner horizontal and vertical
intersection to protect said intersections from unwanted foam
and/or shotcrete over-spray during the construction process.
[0047] FIG. 22 is a perspective drawing of the Drop Rod Alignment
Jig used to join, weld, and finish grind joints between sections of
acme threaded drop rod.
[0048] FIG. 23 is a more detailed perspective drawing of the
suspension components associated with FIG. 9 and is primarily
representative of the Truss Pin Assembly group which supports the
weight of individual floor intersections during the levitating
process.
[0049] FIG. 24 is a more detailed perspective view, on an enlarged
scale, through the wall of FIG. 2 at the base in accordance with
one embodiment of the manner of securing both vertical tension
tubes to the inner base foundation while also securing the air-form
to the outer fringe of the base foundation.
[0050] FIG. 25 is a fragmentary sectional view thru a truss coupler
that is threaded over all welded joints after the above floor has
been lifted into position.
1 REFERENCE NUMBERS: REFERENCE FIG. 8. Twin Shell and/or Multiple 1
Shell Type Structures 9 Shotcrete Outer Shell 1, 2, 4, 6, 8, 20 10
Shotcrete Inner Shell 1, 2, 4, 6, 7 11 Air-Form 1, 2, 4, 6, 10, 11,
12, 13, 24 12 Air lock 1 13 Foundation 1, 2, 4, 10, 11, 24 14
Crushed Limestone 2 15 Polyethylene film 2 16 Urethane vapor
barrier 2 17 Air-Form Lock down 1, 2, 24 Bracket, nut & washer.
18 Horizontal Lock Down 1, 2, 24 "Restraining Rebar" 19 Neoprene
Backing Shoulder of Neoprene and Neoprene Compression Washer 2, 24
20 Sewn Seam/of the Air-Form 4, 10, 11, 12, 13, 24 21 Sewn-in-
Sleeve/of the Air- 4, 6, 10, 11, 12, 13, 18, 24 Form 22
Horizontal/Urethane/Tens- ion 1, 2, 6, 7, 10, 12, 13, 18 Tube 23
Vertical/Urethane/Tension 1, 2, 4, 6, 10, 11, 12, 13, Tube. 14, 18,
24 24 Tension Cable 2, 4, 6, 7, 10, 12, 13, 14, 24 25 Stanchion Cup
2, 6, 10, 11, 24 25A Rebar Cinch 2, 6, 10, 11, 24 25B Cable Crimp
2, 6, 10, 11, 24 26 Urethane 4 Way Cross Connect 10, 12, 13, 18 26A
Cross Connect Access Port 12, 13, 18 27 Urethane Elastomeric 2, 4,
6, 11, 13, 24 Penetrating Resin 28 2 LB density polyurethane 2, 4,
6, 7 foam (outer shell) 29 Long Wire - Broad Plate 2, 4, 5, 6, 17
Hanger bracket 30 Urethane foam 1.5 LB Density 2, 4, 6, 7 (Outer
Shell) 30A Urethane foam 1.5 LB Density 4, 6 (Inner Shell) 31
Urethane foam 1.5 LB Density 2, 4, 6, 7 (Outer Shell) 31A Urethane
foam 1.5 LB Density 4, 6 (Inner Shell) 32 Rebar/Horizontal/Outer
Shell 2, 4, 5, 6, 7, 17, 20 33 Rebar/Horizontal/Inner Shell 2, 4,
6, 7, 20, 21 34 Rebar/Vertical/Outer Shell 2, 4, 5, 6, 7, 17, 20 35
Rebar/Vertical/Inner Shell 2, 4, 6, 7, 20, 21 36 USIS Universal
Snap in 2, 4, 5, 6, 7, 17, 20, 21 Standard. 37 Cell Tube Interior
Void 4, 6, 7, 8 38 Cell Tube 1, 2, 4, 6, 7, 8, 20 39 Truss Rod
Receiver 2, 7 40 Tie Back Rods for Truss 2, 7 Receiver 41 Truss
flange 2, 8 42 Truss ball joint 2, 8 43 Ground plate 2, 8 44 Truss
Slides 2, 8 45 Truss Pin Assembly 15, 23 45A Truss Pin Sleeve
Segment 2, 3, 9, 16, 23 46 Truss bearing 2, 9, 15, 16, 23 47 Truss
beam 2, 3, 8, 9, 15, 16 48 Truss coupler 2, 7, 25 49 Truss sprocket
2, 9, 15, 16 50 Truss Brace 2, 3, 9, 15, 16 51. DC high torque
motor 2, 9, 15, 16 (variable speed) 52 Drive gear 2, 9, 15, 16 53
Acme drop rod (threaded) 2, 3, 9, 15, 16, 22, 23, 25 54 Universal
Snap Clip (USIS 4, 5, 6, 17 Clip) for SIS Braces 55 Assembly
Standard 2, 15, 16, 19 56 Knock Out Plug for Cell 2, 4, 6, 7 Tubes
57 Acrylic Elastomeric Exterior 2, 4, 6, 11, 13, 24 Coating 58
Interior Base 2, 10, 11, 24 59 Air-Form Quadrant Sections 1, 10 60
USIS Brace Receiver Socket 2, 4, 5, 7, 20 61 Drop Rod Alignment and
22 Welding Jig 62 Leveling Bolts 16 63 Galvanized Corrugated 2, 8
Metal Decking 64 Wire Weld Joint 2, 8, 19 65 Stick Weld Joints 2,
3, 9 66 Reinforced Cross Bracing 2, 8 67 In Floor Electrical
Conduit 2, 8 68 In Floor Radiant Heat Tube 2, 8 69 Lightweight
Concrete 2, 8 70 Thread Alignment/Grinding 22 Jig 71 Acme Drop Rod
Joint Grinder not shown 72 Tension Nut of the Assembly 16 Standard
72A Tension Washers 16 73 Tension Spring of the 2, 16 Assembly
Standard 74 Slotted Surface Area of the Assembly Standard 15, 16,
19 75 Grey Iron shank of the Truss 16, 23 Pin 76 Bronze Sleeve of
the Truss 16, 23 Pin 77 Threaded holes in the Grey 23 Iron Shank 78
Horizontal/Vertical Spotting not shown Laser 79 Vertical Spotting
Lasers 19 (singular device) 80 Poly Foam Caps 21 81 Rebar Stop
& Shotcrete at 2, 8 Perimeter Shell 82 Cell Tube Dispenser 20
83 Spring Loaded Line Tension 2, 7, 14 Device 84 Apex Restraining
Frame 2, 7, 14 85 Laser Spotting Device 19 86 Vertical Laser Chase
19 87 Laser Surface Plate 19 88 Calibration Screws 19 89 On/Off
Button 19 90 Final Shotcrete Application 2, 8 after floor
installations 91 Drainage Tile 2 92 Retention Sleeves at Apex 2, 7,
14 Restraining Frame 93 Grid Layout hole 2, 16 94 Styrofoam
blocking 7
DETAILED DESCRIPTION
[0051] Referring now to the drawings, and in particular to FIGS. 1
and 2, a Twin Shell, Multiple Shell and/or Trilithic Dome Shell
type structure constructed in accordance with one embodiment of the
present invention is indicated generally in FIG. 1 and shall be
herein after referred to in general as a Multiple Shell Type
structure or (MST) structure.
[0052] The MST structure illustrated in FIG. 1, takes the form of a
generally semi-spherical shaped dome building having a circular
base defined by a footing or foundation 13 (FIGS. 1, 2, 4, 10, 11,
24) that is preferably formed from concrete to establish the
desired base diameter and is sized to support the weight of the
dome and to withstand various weather and environmental conditions
to which such structures may be subjected.
[0053] Briefly the MST structure is constructed by first setting
the foundation footing 13 (FIGS. 1, 2, 4, 10, 11, 24) after which a
light weight and structurally reinforced air-impervious inflatable
air-form 11 (FIGS. 1, 2, 4, 6, 10, 11, 12, 13, 24) is secured at
its peripheral edge to the footing in an air-tight relation
therewith. An internal restraining system consisting of sewn in
sleeves 21 (FIGS. 4, 6, 10, 11, 12, 13, 18, 24) sewn into the sewn
seam 20 (FIGS. 10, 11, 12, 13, 14) of the air-form into which
extruded urethane tubing 22 & 23 (FIGS. 1, 2, 4, 6, 7, 10, 11,
12, 13, 18, 24) is inserted through which tensions cables 24 (FIGS.
2, 4, 6, 7, 10, 12, 13, 14, 24) are drawn and secured VIA the
interior side of the air-form to the interior base 58 (FIGS. 2, 10,
11, 24) at the interior side of the foundation thereby effectively
limits and restrains the outward force being applied to the
air-form 11 FIGS. (1, 2, 4, 6, 10, 11, 12, 13, 24).
Horizontal/Vertical Urethane tension tubes 22-23 (FIGS. 1, 2, 4, 6,
10, 11, 12, 13, 14, 18, 24) being laced through sewn in sleeves 21
(FIGS. 4, 6, 10, 12, 13, 18, 24) absorb the minimal force that is
needed to hold the air-form in place until the 1.sup.st application
of a urethane elastomeric penetrating resin 27 (FIGS. 2, 4, 6, 11,
13, 24) has been applied followed by a, 2.sup.nd application of
urethane foam 1.5 lb density 30 (FIGS. 2, 4, 6, 7) and finally a
3.sup.rd application of urethane foam 1.5 lb density 31 (FIGS. 2,
4, 6, 7) while long wire broad plate metal hanger brackets 29
(FIGS. 2, 4, 6, 7) are installed only between the 1.sup.st and
2.sup.nd application of urethane foam. The network of tension
cables 24 (FIGS. 2, 4, 6, 7, 10, 12, 13, 14, 24) collectively
termed restraining elements, are configured to allow pressurized
inflation of the air-form while limiting and restraining the extent
of outward inflationary pressure to a defined configuration being
the air-form quadrant section 59 (FIGS. 1, 10). Such quadrant
sections serve to eliminate any possible tearing and/or rupturing
by limiting the stresses within a given quadrant to the much
stronger framework which is supported internally by tension lines
which extend from one side to the other.
[0054] After inflating the air-form 11 (FIGS. 1, 2, 4, 6, 10, 11,
12, 13, 24) a network of rigid urethane tubes 22-23 (FIGS. 2, 4, 6,
7, 11,12, 13, 18, 24) are inserted through sewn in sleeves 21
(FIGS. 10, 11, 12, 13, 18, 24 which are sewn into the air-form
seams 20 (FIGS. 4, 6, 10, 11, 12, 13, 18, 24) thereby allowing
inserted tension cables 24 (FIGS. 2, 4, 6, 7, 10, 12, 13, 14, 24)
to restrain the outward expansion and or lateral movement of the
inflated air-form during the construction process. The placement of
an Apex Restraining Framework 84 (FIGS. 2, 7, 14) of an appropriate
size necessary to interconnect all opposing tension cables 24
(FIGS. 2, 4, 6, 7, 10, 12, 13, 14, 24) to spring loaded line
tension device 83 (FIGS., 2, 7, 14) thereby establishing a uniform
amount of tension to each opposing side of the air-forms urethane
tension tubes 22-23 (FIGS. 1, 2, 4, 6, 7, 10, 11, 12, 13, 18, 24).
Adjusting said tension is accomplished by ratcheting the vertical
tension cable 24 (FIGS. 2, 4, 6, 7, 10, 12, 13, 14, 24) from the
base at one side of the dome while the tension cable line extends
upward and connects to a spring loaded line tension device 83
(FIGS. 2, 7, 14) that spans the apex restraining frame 84 (FIGS. 2,
7, 14) and returns back down the direct opposite side of the dome
shell. Since the vertical lines pull freely through the oversized
urethane tension tubes 22-23 (FIGS. 1, 2, 4, 6, 7, 10, 11, 12, 13,
18, 24), the ratchet can be cranked with,a torque wrench in order
to establish uniform tension levels across all tension lines. In
doing so each side of the shell becomes equally balanced due to the
spring loaded tension device 83 (FIGS. 2, 7, 14) equally splitting
the combined load per line. Lastly, retention sleeves at the apex
restraining frame 92, (FIGS. 2, 7, 14), and stanchion cups 25
(FIGS. 2, 6, 10, 11, 24) into which said urethane tensions tubes
22-23 (FIGS. 2, 4, 6, 7, 10, 11, 12, 13, 14, 18, 24) are inserted
ultimately become bonded together by means of spray applied
urethane elastomeric penetrating resin 27 (FIGS. 2, 4, 6, 11, 13,
24) thereby causing the extruded urethane tubing 22-23 (FIGS. 1, 2,
4, 6, 7, 10, 11, 12, 13, 18, 24) to effectively adhere to the
perforated sewn in sleeves 21 (FIGS. 4, 6, 10, 11, 12, 13, 18, 24)
causing the interconnected network of restraining elements to
effectively restrain the excessive expansion of individual air-form
quadrant sections 59 (FIGS. 1, 10) Once the first urethane
elastomeric penetrating resin coating 27 (FIGS. 2, 4, 6, 11, 13,
24) has cured a slight increase in the internal pressure of the
dome structure effectively causes the air-form quadrant sections 59
FIGS. 1, 10) to pooch whereby a distinctive pattern emerges on the
exterior of the air-form 11 (FIGS. 1, 2, 4, 6, 10, 11, 12, 13, 24).
Thereafter a 1.sup.st layer of urethane foam in a 2 lb density 28
(FIGS. 2, 4, 6, 7) may be applied after which the actual placement
of long wire broad plate hanger brackets 29 (FIGS. 2, 4, 5, 6, 17)
are located by method of directing a precision (commonly available)
horizontal/vertical laser spotting device circumferentially to
allow exact establishment of horizontally and vertically
intersections at which point said long wire broad plate hangers
brackets 29 (FIGS. 2, 4, 5, 6, 17) are affixed. Next a 2.sup.nd
application of urethane foam 1.5 lb density 30 (FIGS. 2, 4, 6, 7)
and a 3.sup.rd application of urethane foam 1.5 lb density 31
(FIGS. 2, 4, 6, 7) followed next by circumferentially attaching all
horizontal outer rebar 32 (FIGS. 2, 4, 5, 6, 7, 17, 20) commencing
at the lowest level on up to the apex of the dome shell by means of
wrapping or twisting said long wire broad plate hanger bracket 29
(FIGS. 2, 4, 5, 6, 17) a two full turns around the horizontal
re-bar commencing from the under side going to the front, up and
then to the rear, and then forward again thus leaving the remaining
length of wire pointing inward horizontally and essentially ready
for the attachment of said vertical outer re-bars 34. (FIGS. 2, 4,
5, 6, 7, 17, 20).
[0055] Once said horizontal rows reach 20' in height, the outer
most vertical re-bars 34 are stood vertical in place by positioning
the lower end of the re-bar on the base foundation, while wire tie
connecting said vertical rebar 34 (FIGS. 2, 4, 5, 6, 7, 17, 20) to
similarly placed vertical rebar protruding upward from the concrete
foundation ring 13 (FIGS. 1, 2, 4, 10, 11, 24). The standing end of
said vertically standing rebar is thereby attached to the outer
horizontal rebar 32 (FIGS. 2, 4, 5, 6, 7, 17, 20) and directly to
the left of the protruding long wire broad plate hanger bracket 29
FIGS. 2, 4, 5, 6, 17). The remaining 8" portion of the long wire
broad plate hanger bracket 29 (FIGS. 2, 4, 5, 6, 17) that was not
used to secure the horizontal re-bar into position will now be used
to lock the vertical outer shell rebar 34 (FIGS. 2, 4, 6, 7, 20)
into position as well. By simply continuing to wrap the outer
vertical outer shell re-bar 34 (FIGS. 2, 4, 6, 7, 20) with the
remaining long wire broad plate hanger bracket wire 29 (FIGS. 2, 4,
5, 6, 17), a secure and precisely located outer shell cross member
configuration is achieved.
[0056] Next the temporary suspension of all horizontally intended
inner re-bars 33 (FIGS. 2, 4, 6, 7, 20, 21) are temporarily
attached VIA hooks to the outer rebar framework half distant
between all exterior horizontal rows prior to the placement of
universal snap in standards or USIS Braces 36 (FIGS. 2, 4, 5, 6,7,
17, 20, 21).
[0057] Next the actual installation of the
universal-snap-in-standards or (USIS Brace) 36 (FIGS. 2, 4, 5, 6,
7, 20, 21) proves to be a very quick and efficient process and does
not compare to any previous art. The individual braces being
snapped onto the previously positioned outer vertical re-bars 34
(FIGS. 2, 4, 5, 6, 7, 17, 21) by means of semi-rigid universal Snap
Clip 54 (FIGS. 4, 5, 6, 17) allows the universal snap in standard
(USIS Brace) 36 (FIGS. 2, 4, 5, 6, 7, 17, 20, 21) to freely rotate
from left thereby facilitating the expedient task of pulling the
previously mentioned (temporarily attached) horizontal inner
re-bars 33 (FIGS. 2, 4, 6, 7, 20, 21) inward and thereby quickly
and efficiently snapping such internal horizontal re- bars 33
(FIGS. 2, 4, 6, 7, 20, 21) into their respective USIS brace
receiver sockets 60. (FIGS. 2, 4, 5, 7, 20).
[0058] Next step is the situating of the inner vertical re-bar 35
(FIGS. 2, 4, 6, 7, 21) in the same manner that the outer vertical
re-bars 34 (FIGS. 2, 4, 5, 6, 7, 17, 20) were previously installed,
only the inner vertical re-bars must be secured by either hand
wiring and/or the preferable use of a hand held automatic wire tie
machine thereby locking the USIS Braces Receiver Socket 60 (FIGS.
2, 4, 5, 7, 20) to the interior horizontal circumferential rebar 33
(FIGS. 2, 4, 6, 7, 20, 21) along with the vertical positioned inner
rebar 35 (FIGS. 2, 4, 6, 7, 20, 21) in one simple operation. This
installation procedure is begun at the lowest level while working
upward to the apex of the dome shell thereby causing the combined
assembly namely both outer and inner constructed re-bar frameworks
to become completely self supporting and therefore no longer
dependent primarily on either the in place air-form, its internal
pressure, and/or the strength of the previously applied foam
urethane shell 28 (FIGS. 2, 4, 6, 7)-30 (FIGS. 2, 4, 6, 7)-31
(FIGS. 2, 4, 6, 7) as in previous art, to support either the
completed Multiple Dome Shell framework and/or other free formed
structures. The framework therefore essentially becomes self
supporting, while the air form and the previously applied urethane
shell remain as a mere attached backdrop to which the sprayed
applied outer shotcrete shell 9 (FIGS. 1, 2, 4, 6, 8, 20) may then
be applied. However, before commencing the application of
shotcrete, it is important that all inner framework intersections
be protected with Poly Foam Caps 80 (FIG. 21) or foil wrap to
prevent fouling such joints with either concrete and/or urethane.
After all universal snap in standards (USIS braces) 36 (FIGS. 2, 4,
5, 6, 7, 17, 20, 21) within a horizontal row have been installed
and locked into position whereby the inner most circumferential
rebar is locked into outward tension, the next row up may proceed
in the same manner thereby repeating the operation until all rows
are completed all the way to the apex of the dome subject to the
following preparatory work.
[0059] All ground plates 43 (FIGS. 2, 8) must be either
mechanically connected to the rebar frameworks of both inner and
outer shells. The ground plate 43 (FIGS. 2, 8) surface must be
covered with a 2" applied thickness of Styrofoam sheet having four
tapered edges on all sides to facilitate access later once the
interior shotcrete surface has hardened, while implanted overhead
truss rod receivers 39 FIGS. 2, 7) must be corked with 3" long
rubber booted rod plugs, while all permanently imbedded mechanicals
must be mechanically attached to the inner framework. Next a first
thin application of outer shotcrete 9 FIGS. 1, 2, 4, 6, 8, 20)
needs to be sprayed directly through the inner as well as the outer
re-bar frameworks whereby the outer shotcrete layer 9 will
accumulate on the previously mentioned urethane backdrop 31. (FIGS.
2, 6, 6, 7). The successive layers of shotcrete thickness will
eventually fully embed all other outer circumferentially first
applied outer horizontal re-bar 32 (FIGS. 2, 4, 5, 6, 17, 20) while
special attention is given to building a much greater thickness of
shotcrete where either universal snap in standards (USIS braces) 36
(FIGS. 2, 4, 5, 6, 7, 17, 20, 21) connect to the vertical outer
rebar 34 (FIGS. 2, 4, 5, 6, 7, 20) thereby causing a high to low
vertical rows around the perimeter of the outer reinforced
framework as particular attention is given to covering all exposed
urethane as well as filling any cavity caused due to the placement
of ground plates 43 (FIGS. 2, 8) and/or truss rod receivers 39
(FIG, 2, 7) being secured back to both outer and inner re-bar
frameworks as in (FIGS. 2, & 17) by means of re-bar tie back
rods 40. (FIGS. 2, 7).
[0060] Next the insertion of vertically positioned cell tubes 38
(FIGS. 1, 2, 4, 6, 7, 8, 20) are achieved by placing
pre-manufactured roll length and wall thickness engineered cell
tubes 38 (FIGS. 1, 2, 4, 6, 7, 8, 20) into cell tube dispenser
cartons 82 (FIG. 20) at the interior base 58 (FIGS. 2, 10, 11) side
of the foundation ring 13 (FIGS. 1, 2, 4, 10, 11, 24) while locking
dispensers squarely between the inner vertical re-bars below the
lowest row of USIS braces 36. (FIGS. 2, 4, 5, 6, 7, 17, 20, 21).
The prefabricated cell tube 38 (FIGS. 1, 2, 4, 6, 7, 8, 20) being
heat sealed at the upper most point and having an attachment
grommet installed, thereby connects to a line cord which runs from
strategically positioned cell tube dispenser's protruding
attachment grommet to a designated height above by being strung
through the erected framework cavity consisting of the outer rebar
framework and the inner framework and separated by vertically
placed USIS Braces 36 (FIGS. 2, 4, 5, 6, 7, 17, 20, 21) and then
dropping vertically back down to the ground. As any or all line
cords are pulled downward its corresponding cell tube rises
(unrolls) from its pre-positioned carton whereby the un-inflated
ribbon of polyethylene film moves upward inside a framework of
steel consisting of the outer horizontal rebar 32 (FIGS. 2, 4, 5,
6, 7, 17, 20) and inner horizontal re-bars 33 (FIGS. 2, 4, 6, 7,
20, 21) and cross connecting USIS Braces 36 (FIGS. 2, 4, 6, 7,
21that are attached to outer vertical rebar 34 (FIGS. 2, 4, 5, 6,
7, 17, 20) and inner vertical re-bars 35 of (FIGS. 2, 4, 6, 7, 20,
21). Some cell tubes 38 (FIGS. 1, 2, 4, 6, 7, 8, 20) will extend
all the way to the apex, while others will terminate at different
levels consistent with the diminishing pattern of vertical rebar
that results due to the natural curvature the shell and/or free
formed structure, while horizontally curved yet vertical stem walls
will all extend full height. Once satisfactorily inflated, the
inlet tube at the base is pinched off with a heat sealing tool that
prevents air from escaping or alternately air pressure may be
maintained throughout the encapsulation process.
[0061] The next step is the application of either light weight
urethane foam and or light weight shotcrete being applied through
the inner horizontal rebar 33 (FIGS. 2, 4, 6, 7, 21) and vertical
rebar 35 (FIGS. 2, 4, 6, 7, 20, 21) framework whereby directing
only enough urethane foam initially to adequately center and hold a
given cell tube within its defined cavity. Said first application
will consist of a minimal thickness of 1.5 LB Density foam urethane
applied in a color coded yellow 1.5 lb density 30A (FIGS. 4, 6)
followed by a second 1.5 lb density foam application only color
coded in a tan 31A (FIGS. 4, 6) followed by a third application of
1.5 lb density foam application in yellow urethane 30A (FIGS. 4, 6)
and lastly a final application of 1.5 lb density urethane foam in
tan again 31A (FIGS. 4, 6) whereupon all tube surfaces are
concealed and thereby render a second flat backdrop upon which the
inner shotcrete layer 10 (FIGS. 1, 2, 4, 6, 7) may be commenced
once all intersections that were protected with poly foam caps 80
(FIG. 21) have been removed.
[0062] Next is the application of shotcrete to the secondary
urethane backdrop to create the internal shotcrete shell 10 (FIGS.
1, 2, 4, 6, 7) is commenced while making certain that the final
finish applications have progressively lesser amounts of 3/8 "or 6
mm gravel so as to achieve a smoother or more uniform interior
surface appearance.
[0063] Once, the interior shotcrete shell 10 (FIGS. 1, 2, 4, 6, 7)
is completed and cured for the prescribed period of time, the
installation of acme or similar type drop rods 53 (FIGS. 2, 3, 9,
15, 16, 22, 23, 25) may commence. By first removing the 3" rubber
boots, which both block and provide access to the recessed truss
rod receiver ports 39 (FIGS. 2, 7)--the appropriate diameter acme
threaded rods may be inserted and threaded into all pre-positioned
truss receivers 39 (FIGS. 2 & 7). As rods are inserted and
extended downward to the base level of the dome a thread alignment
jig 70 (FIG. 22) is used to connect one threaded acme rod to the
next wherein the ends of each acme drop rod 53 (FIG. 22) is tapered
to a point thereby permitting the acme rods to be welded together
both securely and without misalignment. A specially designed die
grinder 71 (Not drawn) once attached to said thread alignment jig
70 (FIG. 22) will effectively grind off any slag or obstructing
weld material that might otherwise deter the passage of the
threaded truss pin assembly 45 (FIG. 23) and or truss rod couplers
48 (FIG. 25) which are both specifically engineered to both climb
and pass over any such weld joints. Such truss couplers 48 (FIG.
25) are revolved up the Drop Rods to override the connection points
whereby further stabilizing all future integrity of the weld joint
just after each successive floor has been elevated up and into
position.
[0064] The particular layout of all suspension points specifically
engineered into a given structure will be first laid out on the
floor of the dome shell by use of grid lay out holes 93 (FIGS. 2,
16) Such holes are precisely located directly below each vertical
load distribution point by physically drilling an appropriately
sized locator hole into the finished concrete floor and/or pilaster
location depending on sequence of floor installation. An assembly
standard 55 (FIGS. 2, 15, 16, 19) will be eventually positioned
over the grid layout hole 93 (FIGS. 2, 16) thereby providing
efficient assembly platforms upon which all floor truss assembly
will follow as well as providing the precise surface to which a
Vertical Spotting Device 79 (FIG. 19) is inserted and used to
precisely project the location at which a truss receiver will be
installed directly overhead. Once all truss receivers are
installed, all acme drop rod drops 53 (FIGS. 2, 3, 9, 15, 16, 22,
23, 25) will be extended all the way down to the floor.
[0065] Once all Acme drop rods 53 (FIGS. 2, 3, 7, 9, 10, 15, 16,
22, 23, 25) are in place the construction of floors to be lofted
into position may commence. The truss floor assembly process begins
by first disconnecting the vertical acme drop rod from the assembly
standards 55 (FIGS. 2, 15, 16, 19). First the Tension Nut 72 (FIG.
16) is backed off relieving the load on the tension spring 73 (FIG.
16) thereby permitting the vertical acme drop rod 53 (FIG. 16)
tension spring 73 (FIG. 16), washers 72A (FIG. 16), and nut 72
(FIG. 16) to be removed. The pre-assembled truss brace 50 (FIGS. 2,
3, 9, 15, 16) through which the truss pin assembly 45 (FIG. 23)
consisting of a grey iron pad 75 (FIG. 23) bronze threaded cylinder
76 (FIG. 23), truss bearing 46 (FIG. 2, 9, 15, 16, 23) and sleeve
segments 45A (FIGS. 2, 3, 9, 16, 23) are first installed after
which a truss sprocket 49 (FIGS. 2, 9,15, 16) is attached to the
underside of the grey iron pad 75 (FIGS. 16, 23) and is elevated
(revolved) up the Acme Rod to just above the height of the assembly
standard 62 (FIG. 16) This maneuver permits the vertical drop rod
53 (FIGS. 16, 23) to be swung back into the slotted surface area of
the assembly standard 74 (FIGS. 10, 15, 16, 19) whereby the truss
tension spring 73 (FIG. 16), truss washers 72A (FIG. 16), and truss
tension nut 72 of (FIG. 16) may be re-secured to the assembly
standard 55 (FIG. 16) thereby achieving its originally tensioned
state.
[0066] Next the attachment of independently controlled and
monitored high torque DC motors 51 (FIGS. 9,16) by which a 3" DIA
drive gear 52 (FIGS. 9, 15, 16) connected to an appropriately sized
truss sprocket 49 (FIGS. 2, 9, 15, 16) to achieve a 8 to 1
reduction from a 500 to 1700 RPM or otherwise sufficiently designed
motor thereby permitting a rate of rise ranging between 9 and 22
feet per hour. This concept allows for efficient and expedient
construction of all floors at ground level and/or bench height in
the most beneficial manner. Such prefabricated floor truss
assemblies consisting of galvanized corrugated metal decking 63
(FIGS. 2, 8) being wire welded into place, whereupon, electrical
conduit, radiant heat tubes are efficiently positioned, and
mechanically fastened to light gauge mesh wire, before partition
walls are placed reduces labor cost dramatically over having to
construct floors at various heights within domes and/or
conventional structures.
[0067] Once the floor truss assembly has been elevated, leveled and
locked into position and said truss flanges 41 (FIGS. 2-8) are
welded back to the ground plates 43 (FIGS. 2, 8) the perimeter
edges are then sprayed from the underside with shotcrete 90 (FIGS.
2, 8) to fully support every lineal foot of perimeter metal decking
abutting the perimeter concrete shell. Additionally, truss couplers
48 (FIGS. 2, 7, 25) are easily revolved up the drop rods by placing
such couplers in advance of truss pin sleeve segments 45A or as
height stops prior to floors being elevated into position. Once
floor is positioned truss coupler 48 (FIGS. 2, 7, 25) will
automatically trigger individual motor stop commands to the control
panel monitoring the lifting process. Such couplers may be then
hand revolved up to span (cover) all welded joints between
floors.
[0068] The remaining step of pumping each floor assembly with
lightweight self leveling concrete which is also a quick process,
while a similar spray application may be used to surface interior Z
panel type wall partitions either before or after the floors are
elevated into position.
[0069] Overall, the outwardly convex bubble-like portions of the
external form having a slightly lesser radius of curvature as
compared to the nominal diameter of the overall dome will not in
and of themselves resist inward buckling of the dome shell,
however, the implementation of the herein defined interconnected
multiple shell system whereby the outer shell is cross connected to
an inner shell with literally thousands of USIS braces 36 (FIGS. 2,
4, 5, 6, 7, 17, 20, 21), will significantly eliminate
snap-through-buckling and/or oil can buckling, while also allowing
lower profile dome shell heights in relation to diameter to be
effectively achieved.
[0070] The plastic insulation foam layer 30 and 31 (FIGS. 2, 4, 6,
7) are techniques described more fully in U.S. Pat. No. 4,155,967,
however, the application of urethanes 30A and 31A (FIGS. 4, 6)
thereby surrounding or encapsulating cylindrical inflated cell
tubes 38 (FIGS. 2, 4, 6, 8) in conjunction with universal snap in
standards (USIS braces) 36 (FIGS. 2, 4, 5, 6, 7, 17, 20, 21) bring
to bear a totally new dimension that is not in any way like prior
art methods of constructing either single thickness thin shell dome
like structure and or concrete vertical stem walls and associated
hollow tube Spancrete type prefabricated segment sections
associated with conventional construction.
[0071] This new art form allows for the creation of multiple shell
configurations having two, three or more shells which are separated
by cell tube interior voids 37 (FIGS. 4, 6, 7, 8) or chase-ways
which may be free formed into place by means of a curvilinear
surface backdrop upon which shotcrete is spray applied whereby
eliminating weight yet interconnecting a universal snap in standard
(USIS brace) 36 (FIGS. 2, 4, 6, 7, 17, 20, 21) system of
prefabricated steel reinforcement rebar thereby permitting live
load capacities to increase in excess of 10 fold because a truss
like relationship are achieved over vast surfaces without
interruptions as are presently experienced by all prior art.
[0072] The illustrated dome building structure 8 (FIG. 1) includes
access means in the form of an entrance door or air lock 12 (FIG.
1) it being understood that the access means is formed in a manner
so as not to impede inflation of the form 11 and may take
substantially any desired configuration and size.
[0073] Windows and/or sky lights and ventilating openings not
shown) may be provided in the finished dome building by adhering
flexible/lightweight Poly-foam segment sections herein defined as
Styrofoam blocking 94 (FIG. 7) to the air-form 11 (FIG. 1) after
the second outer layer of urethane foam 30 (FIGS. 2, 7) has been
applied as is known in the industry.
[0074] The inflatable air form 11 (FIG. 1) is preferably made from
a light-weight air and liquid impermeable flexible sheet or
membrane such as a cross laminate plastic, a reinforced plastic
coated fabric such as polyvinyl chloride impregnated with Dacron,
or other suitable materials.
[0075] The peripheral edge of the air form 11 (FIG. 1) may be
releasably secured in air tight relation to the footing or
foundation 13 (FIGS. 1, 2, 4, 10, 11, 24) by a suitable air form
lock down bracket 17 FIGS. 1 & 24) that holds a suitable
horizontal restraining rod 18 (FIG. 24) that extends around the
foundation. The lower peripheral edge of the inflatable form may be
retained within the peripheral recess formed as a part of the
footing or foundation 13 (FIGS. 2, 24) or secured against a
peripheral vertical surface on the foundation as shown in FIGS. 2
& 24.
[0076] The multiple shell type structure 8 (FIG. 1) consisting of
two or possibly multiple shells may be formed on site and of
substantial size. For Example, the MST structure may have a base
diameter substantially less then or in excess of 300 feet, such as
upwards of approximately 1000 feet or even greater subject to
multiple two ore more shell configurations. A barrel shaped dome
configuration may have a width of approximately 600 feet or greater
and substantially unlimited length subject to multiple shell
configurations which can be now designed to accommodate either
individual dome shell structures as well as conventional structures
by means of multiple vertical stem wall construction, curvilinear
roof over designs and/or massive curvilinear space over concepts as
would be the case with building an enclosed community and/or self
sustaining enclosed microcosm.
[0077] The MST structure 8 (FIG. 1) has an internal network of
restraining horizontal tubes 22 (FIGS. 2, 6, 7, 10, 12, 13, 18) and
vertical restraining tubes 23 (FIGS. 2, 4, 6, 10, 11, 12, 13, 1824)
through which inserted tension cables 24 (FIGS. 2, 4, 6) pass to
both restrain and prevent movement during the construction phase.
This combined network enables the Air-form 11 (FIG. 1) to span
large areas without tearing yet free of external restraint and/or
the need for excessive air pressure within during the construction
phase due to the inherent strength of the interconnecting multiple
shells structural framework that may be efficiently assembled by
using one universal snap in standard (USIS brace) 36 (FIGS. 2, 4,
5, 6, 7, 17, 20, 21) and common steel rebar. This new construction
technology reaches far beyond building residential and commercial
structures in that it can be used to achieve vast space-over
coverage under which a community of homes may be now constructed to
achieve a more secure neighborhood than our present gated
communities, while reducing construction costs and heating costs by
as much or more than 50% of present cost.
[0078] While, preferred embodiments of the present invention have
been illustrated and described herein, it will be understood to
those skilled in the art that changes and modifications may be made
therein without departing from the invention in its broader
aspects.
[0079] Various features of the invention are defined in the
following claims.
* * * * *