U.S. patent application number 11/815724 was filed with the patent office on 2008-06-19 for method of laying a foundation.
Invention is credited to David John Cook.
Application Number | 20080141615 11/815724 |
Document ID | / |
Family ID | 34748260 |
Filed Date | 2008-06-19 |
United States Patent
Application |
20080141615 |
Kind Code |
A1 |
Cook; David John |
June 19, 2008 |
Method of Laying a Foundation
Abstract
A method for laying a foundation that includes the following
steps (a) digging a foundation trench (2), (b) pouring concrete (4)
into the foundation trench to a first level (6); (c) allowing the
concrete to partially cure to a predetermined state; (d) pressing
blocks (10) into the concrete to a desired level equal to the
desired finish height (11) of the foundation; (e) filling the
blocks with sufficient concrete (13) to complete the foundation;
where the predetermined state of the partially cured concrete is
such that the partially cured concrete allows the blocks to be
pressed into the surface of the concrete without risk of sinking
further.
Inventors: |
Cook; David John;
(Christchurch, NZ) |
Correspondence
Address: |
JOHN ALEXANDER GALBREATH
2516 CHESTNUT WOODS CT
REISTERSTOWN
MD
21136
US
|
Family ID: |
34748260 |
Appl. No.: |
11/815724 |
Filed: |
February 9, 2006 |
PCT Filed: |
February 9, 2006 |
PCT NO: |
PCT/NZ2006/000013 |
371 Date: |
August 7, 2007 |
Current U.S.
Class: |
52/741.11 |
Current CPC
Class: |
E02D 27/02 20130101 |
Class at
Publication: |
52/741.11 |
International
Class: |
E02D 27/10 20060101
E02D027/10 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 28, 2005 |
NZ |
538538 |
Claims
1. A method for laying a foundation that includes the following
steps: (a) digging a foundation trench; (b) pouring concrete into
the foundation trench to a first level; (c) allowing the concrete
to partially cure to a predetermined state; (d) pressing blocks
into the concrete to a desired level equal to the desired finish
height of the foundation; (e) filling the blocks with sufficient
concrete to complete the foundation; where the predetermined state
of the partially cured concrete is such that the partially cured
concrete allows the blocks to be pressed into the surface of the
concrete without risk of sinking further.
2. The method as claimed in claim 1 characterised in that, before
step (b) reinforcing is installed.
3. The method as claimed in claim 1 wherein the first level and/or
final block level is set by one or more methods selected from the
list consisting of string level, optical level and laser level.
4. The method as claimed in claim 1 wherein the first level is
laser aligned and/or laser screeded.
5. The method as claimed in claim 1 wherein the final block level
is laser aligned and/or laser screeded.
6. The method as claimed in claim 1 characterised in that, the
blocks are pressed into the concrete to a depth of between 1 mm and
20 mm.
7. The method as claimed in claim 6 characterised in that, the
blocks are pressed into the concrete to a depth of approximately 5
mm.
8. The method as claimed in claim 1 wherein one or more subsequent
building step is commenced during the laying of the blocks.
9. The method as claimed in claim 8 wherein the one or more
subsequent building step includes pouring a shingle fill for a
floor.
10. A foundation prepared by the method as claimed in claim 1.
11. (canceled)
12. (canceled)
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a method of laying a
foundation for a building, more specifically a method for laying a
foundation of a residential dwelling, garage or smaller
commercial/industrial building.
BACKGROUND
[0002] Foundations for smaller buildings are traditionally laid by
a method that includes the following steps: [0003] (i) digging the
foundation trench; [0004] (ii) boxing up the foundation; [0005]
(iii) installing the reinforcing; [0006] (iv) pouring the
foundation; and [0007] (v) removing the boxing, dump or recover
boxing.
[0008] This method is labour intensive, requires boxing and
requires 2 to 3 days to lay a foundation. The boxing needs to be
removed, cleaned and recycled or dumped after use, adding to the
costs. With the variability of the timber used for boxing the
resultant foundation can also need remedial work to correct faults
from warped, badly installed or damaged boxing; this further adds
cost and time to the process.
[0009] A second method, used where the cost of concrete is high,
includes the following steps: [0010] (ia) digging the foundation
trench; [0011] (iia) pouring the foundation; [0012] (iiia) pouring
the foundation, to a level below the top of the trench; [0013]
(iva) allowing the foundation to cure until rigid; [0014] (va)
laying blocks on top of concrete; and [0015] (via) filling block
cavities with concrete to complete the foundation.
[0016] This second method removes the cost of the boxing and
inherent cleanup, disposal and recycling of boxing steps. This
method also dispenses with the labour costs and time associated
with the boxing. It does however add the cost of a sub-contractor
to lay the blocks, which can add substantially to the cost of the
foundation and depends on the availability of that sub-contractor.
This second method adds the cost of mortar to lay the blocks and
can take about two days due to the requirement for a block
layer.
[0017] With the cost of labour being one major cost associated with
the laying of a foundation and increasing time pressures being
placed on building projects there is a need for an improved method
of laying a foundation that reduces the time taken to lay a
foundation. This improved method ideally needs to avoid boxing and
the associated problems, and if possible reduce or remove the need
for additional sub-contractors. However any improved method must
not compromise the quality or longevity of the final
foundation.
OBJECT OF THE INVENTION
[0018] It is therefore an object of this invention to provide a
method of laying a foundation that can reduce the time taken and
overall cost of the foundation when compared to traditional
methods.
[0019] It is a further object of the invention to reduce the cost
of laying a foundation over traditionally employed methods, without
compromising the integrity of the foundation.
DISCLOSURE OF THE INVENTION
[0020] The present invention provides a method for laying a
foundation that includes the following steps: [0021] (a) digging a
foundation trench; [0022] (b) pouring concrete into the foundation
trench to a first level; [0023] (c) allowing the concrete to
partially cure to a predetermined state; [0024] (d) pressing blocks
into the concrete to a desired level equal to the desired finish
height of the foundation; [0025] (e) filling the blocks with
sufficient concrete to complete the foundation; where the
predetermined state of the partially cured concrete is such that
the partially cured concrete allows the blocks to be pressed into
the surface of the concrete without risk of sinking further.
[0026] Preferably before step (b) reinforcing is installed.
[0027] Preferably the first level and/or final block level are set
by string level, optical level or laser level. It is highly
preferred that the first level and/or final block level are laser
aligned and/or laser screeded.
[0028] Preferably the blocks are pressed into the concrete to a
depth of between 1 mm and 20 mm, an optimum depth being
approximately 5 mm.
[0029] Subsequent building steps can be commenced during the laying
of the blocks, for example pouring the shingle fill for the floor
can be commenced.
[0030] The present invention also includes a foundation prepared by
the method described above.
DESCRIPTION OF THE DRAWINGS
[0031] By way of example only, a preferred embodiment of the
present invention is described in detail with reference to the
accompanying drawings, in which:--
[0032] FIG. 1 shows a flowchart of the method;
[0033] FIG. 2 shows a cross sectional view along the foundation
trench of the invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0034] Referring to the drawings the present method for laying a
foundation (1) includes a first step (A) where a foundation trench
(2) is formed in the standard way, this is followed by a second
step (B) which involves the installation into the foundation trench
(2) of initial reinforcing (3) which is part of the complete
reinforcing required to meet the local standards.
[0035] In the third step (C) concrete, of standard grade, is poured
into the foundation trench (2) as a concrete platform (4). The
concrete platform is laser screeded, i.e. the surface (5) of the
concrete platform (4) is precisely adjusted to the required level
(6) using a laser level of standard design. This required level (6)
allows one or more concrete blocks (10) to be inserted into the
concrete platform (4) to a depth of between 0 mm and 20 mm in a
fifth step (E).
[0036] In the fourth step (D) the concrete platform (4) is allowed
to partially cure; this partial cure is sufficient to maintain the
position, without sinking, of the or each concrete block (10)
inserted into the concrete platform (4) in the fifth step (E) in
position without requiring excessive force. Excessive force in this
context is a force that would cause the concrete platform (4) to be
permanently damaged.
[0037] In the fifth step (E) the or each concrete block (10) is
inserted into the surface (5) of the partially cured concrete
platform (4), and the height of a top (11) edge of the or each
concrete block (10) is adjusted to the required height using a
laser or string level. The or each concrete block (10) is butted up
against each adjacent concrete block (10).
[0038] The sixth step (F) includes the installation of final
reinforcing (12) which completes the complete reinforcing. The
seventh step (G) includes the filling of the or each concrete block
(10) with a concrete fill (13) to complete the foundation.
[0039] As the seventh step (G) is being completed it is possible to
start pouring the shingle required for the floor slab, and in fact,
if the correct grades of concrete are selected, the floor laying
stages could be commenced the same day as completing the
foundation.
[0040] The present method therefore does not require the use of
boxing and therefore the time, material and costs associated with
boxing are avoided. In addition there is no requirement for a
sub-contracting block layer to be involved, thus the cost and time
associated with this is avoided. These savings are achieved without
compromising the longevity or quality of the foundation.
* * * * *