U.S. patent number 3,643,910 [Application Number 04/805,143] was granted by the patent office on 1972-02-22 for inflatable forms.
Invention is credited to Haim Heifetz.
United States Patent |
3,643,910 |
Heifetz |
February 22, 1972 |
INFLATABLE FORMS
Abstract
Inflatable forms for use in the construction of shells, such as
shells used in building, from material such as concrete, plastic
materials or the like which is cast or gunned on the form after the
latter has been inflated. In particular the invention deals with
base ring structures for use with such forms.
Inventors: |
Heifetz; Haim (Haifa,
IL) |
Family
ID: |
11044382 |
Appl.
No.: |
04/805,143 |
Filed: |
March 7, 1969 |
Foreign Application Priority Data
|
|
|
|
|
Mar 7, 1968 [IL] |
|
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29599/68 |
|
Current U.S.
Class: |
249/65; 264/32;
425/135; 249/13; 264/314; 425/389 |
Current CPC
Class: |
E04B
1/169 (20130101); E04G 11/04 (20130101); E04H
15/20 (20130101); E04H 15/22 (20130101); E04G
11/045 (20130101) |
Current International
Class: |
E04G
11/04 (20060101); E04H 15/20 (20060101); E04G
11/00 (20060101); E04H 15/22 (20060101); B28b
007/32 () |
Field of
Search: |
;249/1,13,18,65
;25/1B,128D,13A,131.5A,131.5B,131.5C,131.5D,131.5G ;52/2
;264/32,314 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Overholser; J. Spencer
Assistant Examiner: Frye; Lucius R.
Claims
I claim
1. Pneumatically inflatable form apparatus for use in the
construction of shell-form structures, said apparatus comprising a
stress resisting base assembly which includes a rigid, perimeter
defining structure and a transverse structure extending across and
connected to said perimeter defining structure, said
perimeter-defining structure comprising a rigid base ring of
predetermined shape and said transverse structure comprising a
plurality of elongated stress transmitting members extending across
and anchored to the base ring, a flexible inflatable form having a
peripheral rim and a flexible base, means securing said rim to said
perimeter defining structure with said flexible base resting on
said transverse structure, said base assembly being sufficiently
rigid to oppose, independently of external forces, deflection of
said flexible base upon inflation of said form, said base assembly
together with said form constituting a closed force system which
prevents interiorly exerted pneumatic forces within said form from
acting as elevating forces on said perimeter defining
structure.
2. Apparatus according to claim 1, wherein said base ring comprises
a plurality of rigid curved segments and means coupling said
segments together.
3. Apparatus according to claim 2, wherein said means securing said
rim to said perimeter defining structure comprises a plurality of
clamping elements attached to the segments and means for tightening
the clamping elements against the segments with said peripheral rim
squeezed between said segments and said clamping elements.
4. Apparatus according to claim 1, wherein said transverse
structure comprises a plurality of elongated tensioning members
extending across and anchored to the base ring.
5. Apparatus according to claim 4, wherein said transverse
structure further includes a centrally located hub and wherein said
tensioning members extend radially from said hub to said base
ring.
6. Apparatus according to claim 1, wherein said transverse
structure comprises a plurality of radial struts with outer ends
bearing on the base ring and inner ends located out of the plane of
said base ring in the direction of said form.
7. Apparatus according to claim 6, wherein said radial struts are
configured to form a low dome-shaped structure which fits within
said form.
8. Apparatus according to claim 1, wherein said base assembly is
collapsible and removable from a shell-form structure constructed
about said apparatus.
9. Apparatus according to claim 2, wherein said peripheral rim is
formed in the configuration of an annular pocket which extends
around the form where the flexible base joins the form.
10. Apparatus according to claim 9, wherein said pocket contains an
anchoring pipe.
11. Apparatus according to claim 10, wherein the anchoring pipe is
a flexible hollow tube connected to a source of fluid pressure.
12. Apparatus according to claim 10, wherein said annular pocket
and anchoring pipe are held by clamping elements connected to the
base ring.
13. Apparatus according to claim 1, further including a plurality
of transversely extending members anchored to the perimeter
defining structure and located above the inflatable form, said form
being positioned to inflate downwardly with said flexible base
pressing upwardly against said transversely extending members
whereby said transversely extending members become embedded in
casting material poured over the apparatus and as so embedded,
serve as reinforcing members for the casting material.
Description
This invention relates to inflatable forms of the kind which have
been proposed for use in the construction of shells for use in
building, such shells being formed by the casting or gunning of
cementitious or plastic materials or the like on the form after the
latter has been inflated. Various proposals have hitherto been made
for the use of inflatable forms in building construction. None of
these prior proposals, however, have led to a practical economic
method of construction and, in consequence, there has been very
little exploitation or development of the idea.
It has now been found that the successful use of inflatable molds
in building construction depends on satisfying the following
conditions:
1. The facility for ready inflation and deflation of the form and
its removal from the cast shell for subsequent reuse;
2. The maintenance of a predetermined shape, location and set of
dimensions of the inflated form during casting and setting of the
shell and the predetermined shaping of any openings therein;
and
3. The ability of the form and associated structure to withstand
and/or counteract the very substantial elevating forces which act
thereon as a consequence of inflation, such forces becoming
critical with large forms and tending to raise the form and its
foundations from the ground.
None of the prior proposals satisfy in their entirety any of these
conditions and certainly fail to satisfy all the conditions.
As far as the first condition is concerned, no practical provision
seems to have been made in accordance with the prior proposal for
the designing of the form in such a fashion as to facilitate its
ready removal from the cast shell and its subsequent reuse. It will
be readily appreciated that an inability to reuse the form would
weaken, if not entirely remove, the economic basis for the system.
Furthermore, in most of the prior proposals where means are
suggested for disassembling and removing the form after use, the
form is described as being anchored to a base at discrete anchoring
points. In other words, there is a concentration of tension at
these specific points consequent upon inflation of the form with a
consequent increased likelihood of rupture of the form at these
points thereby rendering the form incapable of further use.
Alternatively, any form which is designed so as to avoid these
dangers would be of entirely uneconomical weight and strength.
In accordance with some of these prior proposals the second
condition referred to above was to be satisfied by inflating the
form to a very high pressure (pressures of between 2 to 5 lbs per
square inch having been proposed). Such proposals have been
recognized as impracticable seeing that they involve the provision
of forms made of flexible materials capable of withstanding very
considerable forces and such materials, even if available, are
prohibitively expensive. In contrast, other proposals have involved
inflating the form to a relatively low pressure (pressures of the
order of 2 oz. per sq. inch have been proposed in this connection).
With such low pressures, however, it has proved to be very
difficult if not impossible to control the shape, location and
dimensions of the form, these being very susceptible to distortion
by the weight of the applied materials and the force of application
as well as to external influences such as variations in
temperature, winds or the like. In consequence, domes produced
under such conditions are subject to disintegration in view of the
development of planes of rupture and it has in fact been proposed
to provide such forms with expensive reinforcing rings designed to
support the shell during application and setting.
In none of the prior proposals is the third condition referred to
above mentioned, let alone any construction suggested so as to
enable the form to meet this condition.
It is an object of the present invention to provide a new and
improved inflatable form for the purpose referred to which is
capable of use so as to satisfy some or all of the conditions
referred to above.
According to the present invention there is provided an inflatable
form for the purpose referred to and having a rim portion secured
to or adapted to be secured continuously to a rigid or rigidizable
base ring associated therewith and being so constructed as to be
capable of resisting compressive or tensioning forces exerted
thereon.
The base ring can, if required, be anchored to an appropriate
foundation. Alternatively, the base ring can be maintained
completely detached from any such foundation thereby facilitating
the use of the form in the production of prefabricated shells
designed for subsequent transport to a site.
The form is preferably manufactured of a material which is
minimally extendable. Seeing that it is to all intents and purposes
impossible to utilize for this purpose a completely unextendible
material, which would still be within the realm of economic
feasibility, steps have to be taken to ensure that the extension or
stretching of the form material during inflation should be entirely
predetermined and as uniform as possible. In view of the fact that
it is precisely at the rim region of the form, where it is
connected to the base ring, that stretching is inhibited it is
essential, in order to ensure a uniform deformation of the material
during inflation, to have these rim portions prestretched to a
degree comparable with the stretching of the remainder of the form
during inflation.
A form of this kind in accordance with the present invention is
particularly adapted for use with pressures of inflation which are
not so high as to require form materials of exceptional strength or
so low as to render difficult if not impossible the maintenance of
the form shape against the distorting effect of the weight of the
applied material and against extraneous disturbing influences, such
as winds, temperature variations or the like.
Thus, pressures of inflation of the order of 30-60 g./cm..sup. 2
can suitably be employed, the actual pressure depending, inter
alia, on the size (diameter) of the form.
It will be understood that suitable control means must be provided
to ensure that the pressure of inflation is maintained within
well-defined limits (e.g., .+-. 1 g./cm..sup. 2) during casting and
setting of the shell. Similarly, measures have to be taken so as to
ensure that the ultimate shape of the inflated form is as
predetermined. Such measures are particularly required during the
critical setting stage when the materials while inelastic are
nevertheless still very sensitive to deformation.
The feature of having the form secured to or adapted to be secured
to a rigid or rigidizable base ring facilitates the ready removal
of the form from the constructed shell after the latter has set
while the fact that the form is continuously secured at its rim to
this base ring ensures the uniform distribution of stress in the
form and thereby greatly reduces the danger of rupture of the form
which arises when the form is secured at discrete points to a
base.
A form provided with a base ring in accordance with the present
invention can readily be adapted to withstand the very considerable
elevating forces acting on the form and on its base ring when the
form is inflated. For this purpose the form, which in this case is
integral with a base portion so that the form and the base portion
constitute a sealed whole has its base ring associated with a
plurality of transversely directed cables, rods or the like
anchored thereto, the arrangement being such that when said cables
are tensioned said ring is placed in compression.
With such an arrangement the elevating forces previously referred
to are transmitted through the base portion of the inflated form,
which would otherwise assume a spherical shape, to the transversely
directed cables and this downwardly directed force is transformed
into transversely directed tensioning forces in the cables which in
turn serves to put the base ring into compression. Alternatively,
the base ring is associated with a plurality of radially directed
struts or trusses, as a result of which, the downwardly directed
forces are transformed into radially directed compressive forces
which serve to tension the base ring. In effect, therefore, the
form and its associated base structure (base ring and transverse
cables or struts) constitute a closed force system, i.e., all
forces developed in the system are retained therein and are
substantially not transmitted outside the system, e.g., to the
ground. By virtue of this arrangement it is possible to provide
forms of very considerable dimensions in which the effect of the
elevating forces on the foundations of the form would be otherwise
so large as to require either the provision of extremely heavy
foundations or anchoring devices or the excavation of a
hemispherical cavity below the form. None of these solutions are
economically feasible.
In accordance with a preferred embodiment of the present invention
said form is provided with an integrally formed flexible base, the
form and base constituting an inflatable sealed unit and being
located between respective sets of transversely directed tensioning
cables, rods or the like anchored to a base structure.
Such an embodiment can be readily employed for the construction of
ceilings, roofs, floors or the like on, or for transport to a site.
Thus, upon inflation, the upper set of tensioning cables limits the
maximum curvature of the form and the concrete or other
cementitious material can be applied to the form, the upper set of
cables becoming embedded therein and serving as reinforcements. On
the other hand the lower set of cables serve to take up the
downwardly directed forces consequent upon inflation of the form
transforming them into tensioning forces which in their turn serve
to put the base ring of the form into compression. In the case of
this embodiment as in the case of the previous embodiment the
entire assembly constitutes a closed force system.
Various embodiments of the present invention will now be described
by way of example and with reference to the accompanying drawings
in which:
FIG. 1 is a schematic sectional view of an inflated form and
associated base structure in accordance with the present
invention,
FIG. 2 is a schematic flow diagram of the air supply and control
system used for inflating the form,
FIG. 3 is a perspective view of a portion of the base structure of
the form shown in FIG. 1,
FIG. 4 is a front elevation of a detail of the base structure shown
in FIG. 3 showing the mode of coupling together of the constituent
segments of the base structure,
FIG. 5 is a cross-sectional view of the base structure shown in
FIG. 3 in a position ready to receive the form rim,
FIG. 6 is a similar view to that of FIG. 5 but with the form rim
shown firmly clamped in position,
FIG. 7 shows, in schematic plan view, a length of anchoring pipe
associated with the form rim,
FIG. 8 is a perspective view showing the mode of entry and exit of
the anchoring pipe through the base structure,
FIG. 9 is a longitudinal sectional view of a form of the kind shown
in FIG. 1 with a superimposed smaller form,
FIG. 10 is a detail of the view shown in FIG. 9 on an enlarged
scale,
FIG. 11 shows schematically a hemispherical shell formed on a form
in accordance with the invention and provided with lifting
cables,
FIG. 12 is a view, on an enlarged scale, of a detail of the shell
as shown in FIG. 11,
FIGS. 13a 13b are respective plan and sectional views of the
surface of a form reinforced with hexagonal plates,
FIG. 14 is a sectioned side elevation of a composite form and
associated cable structure,
FIG. 15 is a perspective view of the cable structure shown in FIG.
14,
FIG. 16 is a perspective view of a portion of the composite form
and cable structure shown in FIG. 14 with a portion of a cast shell
roof or radial slab,
FIG. 17 is a perspective view of a building showing the use of a
composite form and cable structure for constructing the roof,
FIG. 18 is a perspective view of a window form and clamp associated
with an inflatable form,
FIG. 19 is a longitudinal sectional view of the clamp and form
shown in FIG. 18 embedded in concrete,
FIG. 20 is a plan view of a portion of a modified and reusable base
structure in accordance with the invention,
FIG. 21 is a cross-sectional detailed view of a portion of the base
structure shown in FIG. 20 taken along the line XXI--XXI,
FIG. 22 is an enlarged plan view of a detail of the base structure
shown in FIG. 20, and
FIGS. 23, 24 and 25 are schematic longitudinal sectional views
respectively of three modifications of inflated form and associated
reusable base structure in accordance with the invention
facilitating the construction of a substantially "foundation-less"
structure.
As seen schematically in FIG. 1 of the drawings, a flexible
hemispherical form 1 is anchored at its rim 2 to a base structure
3. The structure 3 consists of an annular base ring 4 and a
transverse cable-tensioning structure 5. The latter consists of an
inner ring 6 and radially directed tensioning cables 7. Each cable
is secured at its inner end to the inner ring 6 and at its outer
end to the annular base ring 4. The form 1 is formed integrally
with a flexible base 8 adapted to rest on the transverse cable
tensioning structure 5.
The form 1 is provided with an air inlet conduit 9 whose
association with the form, and whose coupling to a source of
compressed air via a suitable pressure control means is illustrated
in detail in FIG. 2 of the drawings.
The form rim 2 is associated with an anchoring pipe illustrated in
detail in FIGS. 6 and 7 of the drawings and a pressure fluid supply
for this anchoring pipe is introduced via a supply conduit 10.
As seen schematically in FIG. 2 of the drawings, the form 1 is
supplied with compressed air from a compressor 11. The form 1 is
coupled to an automatic control valve 12 via a control conduit 13
which projects into the interior of the form 1 and is capable of
sensing the pressure conditions prevailing in the form interior a
conduit 14 couples the interior of the form 1 with a control
mechanism 15. The control valve 12 is regulatable by means of the
control mechanism 15 which is provided with an outlet 16. In use,
the automatic control valve is set to regulate at a given pressure
level by means of the control mechanism 15 and, upon actuation of
the compressor 11, the form is inflated, the pressure level in the
form being thereafter maintained substantially constant.
Reference will now be made to FIGS. 3 to 8 of the drawings for a
clear illustration of the base structure of the form and its
coupling to the form itself. As can be seen in the drawings, the
base structure consists of a base ring 4 comprising a plurality of
channel-shaped segments 21 and a plurality of clamping elements 22.
The channel-shaped segments 21 are coupled together so as to form a
ring by means of coupling elements 23 of U-shaped cross section
which, as can be seen in FIG. 4 of the drawings, are inserted in
the adjacent ends of respective pairs of segments, and are bolted
thereto. The clamping elements 22 are coupled to the channel-shaped
segments 21 by means of clamping bolts 24, which extend through
corresponding apertures formed in the segments 21, clamping nuts 25
being provided for the bolts 24. Thus in the position shown in FIG.
5 of the drawings, the clamping element 22 is displaced from the
channel-shaped segment 21 so as to be ready to receive the form
rim, while, as shown in FIG. 6 of the drawings, the clamping
elements 22 are clamped tightly against the channel-shaped segments
21 firmly retaining the form rim in position. Each clamping element
22 has a "question-mark" profile the curved section 26 of which is
designed to receive the form rim, whilst the vertical limb 27 of
which is designed to be clamped against the channel-shaped segment
21.
The clamping of the form rim by the clamping elements not only
serves to anchor the form to the base structure, but also serves to
impart to the form rim a degree of prestretching. This
prestretching is in many instances essential, in order to ensure
that the inflated form achieves the predetermined shape.
One set of ends of radially directed tensioning cables 28 extend
respectively between adjacent clamping elements 22 through
apertures formed in the channel-shaped segments 21 and associated
coupling elements 23 and clamping plates 29 to which they are
firmly bolted. The outer and inner set of ends of the radially
directed cables 28 are respectively secured to an inner ring
30.
The lowermost edge or rim of the form 1 and form base 8 is formed
integrally with a double walled skirt portion 31 in which is
located a flexible anchoring pipe 32 the ends of which extend out
through appropriate elongated apertures formed in the
channel-shaped segment 21 to be connected to a pressurized water or
other fluid source. As clearly seen in FIG. 7 of the drawings, a
dummy pipe section 33 is interposed in the clamping element so as
to fill the space between the bent over portions of the clamping
pipe 32.
The assembly of the form takes place as follows. The form, made of
a minimally stretchable material, together with the form base 8 and
anchoring pipe 32 as described above, is brought to the site and is
spread out thereon. The clamping elements 24 are loosened and, in
their loosened position, the rim of the form (including the
anchoring pipe 32) is inserted into the curved section 26 of the
clamping elements 22, the two ends of the anchoring pipe emerging
through the apertures as shown. With the form rim in position the
clamping elements 22 are clamped firmly against the channel-shaped
segments 21 by a tightening of the clamping bolts and water, or
other fluid under pressure is forced into the anchoring pipe 32
causing it to expand so as to fill the space between the curved
section of the clamping elements and the channel-shaped segment and
thereby securely anchors the form to the base structure. As an
alternative to the use of a fluid filled anchoring pipe a flexible
cable made for example of rubber may be employed.
With the form 1 thus anchored to the base ring and with the
tensioning cables 28 having been previously given a predetermined
degree of slackness by turning the clamping bolts which are
distributed around the periphery of the channel-shaped segments 21,
the form 1 is inflated to the required working pressure depending
on the size of the form (for example 30-60 g./cm..sup.1). The
control valve 12 is employed to ensure that the pressure remains
substantially constant at the required level during the subsequent
application of the cementitious or other material and its
setting.
In addition to ensuring that the form is inflated to and maintained
at the required pressure it is also necessary to ensure that the
form acquires, upon inflation, the required stability and its
predetermined shape and for this purpose visual observation means
are employed. With the inflation of the form, the downwardly
directed forces, acting on the form base and tending to force that
base to assume a spherical shape, are transmitted to the tensioning
cables 28 and result in the further tensioning of these cables,
these tensioning forces being transmitted to the base ring which
absorbs these forces. Thus, the form and its associated base
structure constitute a closed force system and forces developed in
this system as a result of the inflation of the form are
substantially maintained within the system and not transmitted out
of the system. In other words these downwardly directed forces are
prevented from acting on the ground and thereby subjecting any
foundations of the form to overwhelming elevating forces. The
construction of this closed force system renders it possible to
ignore completely the effects of these elevating forces and as a
consequence there is no necessity of anchoring the base ring to the
ground. This anchoring can take place if desired or can be
dispensed with if not required.
With the form anchored and inflated as described above, a layer of
quick-hardening material such as for example gypsum is applied to
the form and when this has set to form a shell the form is
deflated, the clamping elements loosened, the anchoring pipe
emptied of its water and the form removed from the shell via an
opening which has been left in the shell for this purpose. There
can then be applied to the shell one or more layers of cementitious
material. If desired pretensioned reinforced rods can be embedded
in the layers of the cementitious material thus applied having been
preliminarily anchored to the base ring. In this way hemispherical
dome can be easily and inexpensively constructed on an inflatable
form. In the example just described this dome is formed on the
channel-shaped base ring which sits freely on the ground and the
dome can therefore be transported to any suitable site. If desired,
however, the base ring can preliminarily be embedded in a concrete
foundation, in which case the dome is permanently cast on the
predetermined site.
With the casting and setting of the shell the tensioning cables and
central ring can, if desired, be removed. Alternatively, these
tensioning cables which are now in a tensioned state, can be
allowed to remain so as to become embedded in a subsequently cast
concrete floor thereby providing reinforcement for the floor which
is suspended on its base ring.
FIGS. 9 and 10 show how a small superstructure 35 can be cast on an
auxiliary inflatable form 36 anchored to a dome 37 which has been
previously cast on a main inflatable form. Thus, as can be seen in
the drawings, and in particular in FIG. 9 thereof, a cylindrical
(preferably transparent) base ring 38 is supported by means of a
lower flange 39 on the rim of an upper central aperture 40 of the
dome 37. This cylindrical "base ring" 38 surrounds a cylindrical
wooden form 41 having a circular wooden lid 42. An auxiliary
inflatable hemispherical form 43 is secured at its rim to the
cylindrical wooden form 41, the base 44 of the auxiliary form 43
bearing on the upper surface of the wooden lid 42. An auxiliary air
inlet pipe 45 passes through the "base ring" 38 and the wooden lid
42 into the inner space of the auxiliary form 43 and in this way
the auxiliary form 43 can be inflated. After inflation to the
required pressure the cementitious material is cast on the
auxiliary form 43 and after it has set the auxiliary form 43
together with the wooden form 42 are removed leaving the auxiliary
domelike superstructure 35 and the cylindrical transparent fanlight
38.
As indicated above the shell can be prefabricated on a base ring
and can then be transported to a site on which it is to be erected.
A convenient method of transporting such shells, especially to
relatively inaccessible sites can be by helicopter. For this
purpose, and as seen in FIGS. 11 and 12 of the drawings, the shell
is provided with lifting cables 47 which are coupled to a single
suspension cable 48 designed to be coupled to a helicopter. FIG. 12
shows clearly how the lifting cables 47 are secured to lugs 49
which are in their turn secured to the base ring.
A particularly advantageous use of such transportable shells is in
connection with sealed medical units such as for example
field-operating theaters. For this purpose the shells can be
prefabricated in the manner described above from a lightweight
material such as, for example, polystyrene reinforced with glass
fibers. The shell thus produced is provided with a lightweight
flooring (e.g., of polyethylene) which rests on the tensioning
cables and which serves to seal the unit which will have been
rendered sterile. The unit can be fully equipped with all the
necessary medical equipment and can be readily transported by
helicopter together with the medical team so that any injured
person can be operated on, on the site.
From the description which has just been given it will be realized
that the base ring, which constitutes an essential element of the
base structure associated with the form, serves a plurality of
vital functions among which are the following:
1. A rigid annular structure to which the form can be continuously
anchored;
2. An annular structure to which can be anchored transversely
directed tensioning cables (or, as will be described below, radial
struts or trusses) designed to take up the elevating forces which
would otherwise act on the foundations of the form and to transform
them into compressive or tensioning forces for the ring;
3. A base from which can be secured reinforcing cables to be
embedded in the cementitious material forming the dome which is set
for a suitable means for securing the dome to a base to which it is
to be anchored.
While in the arrangements specifically described above the form is
clamped to a rigid base structure, the base ring can conveniently
be formed as a rigidizable structure. Thus, under certain
circumstances, the metal base ring can be dispensed with and the
anchoring pipe can be adapted so as itself to constitute the base
ring on the structure, which can in its turn form an anchoring ring
for the transversely directed cables.
The form should be constructed of a flexible material of low
elasticity. A suitable material is natural or synthetic rubber
which can, if required, be suitably reinforced by means, for
example, of natural or synthetic fibers. Thus, the form can be
constituted for example of a fabric formed of cotton or nylon
fibers, the fabric being impregnated and covered with natural or
synthetic rubber. The degree of reinforcement and strength of the
form is of course determined by the stresses to be imparted to the
form as a result of inflation thereof and casing thereon of the
concrete shell. Suitably the form is constructed in the form of
segments which are secured together by bonding, welding, sewing or
the like so as to constitute the shape required. The segments can
be arranged to overlap so as to impart a further degree of
reinforcement to the form itself.
In the embodiment schematically illustrated in FIGS. 13a and 13b of
the drawings, the form is constituted by rigid hexagonal plates 57
which can be formed of a suitable rigid material (e.g., hard
rubber) which are bonded onto a flexible base at such a spacing
that the entire structure remains flexible but assumes a
hemispherical form when inflated.
Reference will now be made to FIGS. 14, 15 and 16 of the drawings
wherein are illustrated the construction of a composite form and
cable structure and its use in the construction of reinforced
concrete, roofs or floors. The composite structure comprises a
peripheral base ring 61 to which is peripherally secured an upper
flexible form 62 and an integrally formed lower flexible form base
63. The upper form 62 and lower form base 63 are respectively
enclosed between an upper set of form limiting cables 64 and a
lower set of tensioning cables 65. Both sets of cables are
respectively secured at their outer sets of ends to the base ring
61.
In a similar manner to that described above, the cables of each set
are radially disposed and are secured at their inner ends to an
inner ring 66 and at their outer ends to the base ring 61. FIG. 15
shows clearly the construction of the two sets of cables 64 and 65
with the interposed form and base removed.
As can be clearly seen in FIG. 16 of the drawings, the base ring 61
consists of segments 67 of rectangular cross-sectioned shape, which
are coupled together (by means not shown) so as to conform to the
desired peripheral shape of the form. Secured to the segments 67,
in a manner similar to that described above, is a plurality of
clamping elements 68 which are substantially identical in
construction with the clamping of the combined rim of the upper
form 62 and lower form base 63. The outer ends of the two sets of
cables pass through the segments 67 and are secured thereto,
tensioning of the cables being possible at their inner ends.
In the use the composite form and cable structure is assembled so
that the base ring 61 rests on a prepared structure on which the
floor or ceiling is to be cast. Thus, as can be seen in FIG. 17 of
the drawings, the composite structure is placed on the upper edge
of a cylindrical building and is used to cast a roof for the
building. The form is then inflated, it being ensured that
inflation takes place to the desired pressure and this pressure is
maintained during casting of the material and subsequent setting.
The upper set of cables 64 serve to delimit the degree of inflation
of the form and thereby ensure the relative flatness of the form
and the structure subsequently to be cast thereon. The lower set of
cables 65 on the other hand serve to take up the downwardly
directed elevating forces which are created in the form base as a
result of its inflation, these forces being converted into
tensioning forces of the cables which are in turn transmitted to
the base ring 61. Cementitious material, such as concrete, is cast
on the form, the upper form limiting cables becoming embedded in
the concrete and serving to reinforce the concrete. If necessary
and desired (especially in connection with large structures) the
radially directed, form limiting, and concrete reinforcing cables
can be bridged by transverse reinforcing elements in the form of
cables, wire mesh or the like.
After the cementitious material, such as concrete has been cast on
the form to the required depth, completely embedding the upper set
of cables, the material is allowed to set after which the form is
deflated and removed, leaving the cast roof or floor in
position.
It can be shown theoretically that a structure cast on a composite
form and cable structure in accordance with the present invention
and as just described, enjoys special strength characteristics over
and above structures constructed in a conventional manner. Thus it
is possible to use this method for covering very substantial areas,
such as sports stadiums, swimming pools, shelters or the like. The
method is particularly economical as it can be carried out using a
very thin layer of concrete and the degree of support for such a
structure is also minimum.
While in the examples specifically described above the tensioning
cables have always been shown to be disposed radially, embodiments
can equally well be conceived where the tensioning cables are
disposed in other transverse directions.
The provision of a domelike shell, constructed in accordance with
the present invention, with windows can be effected by means of the
combined window form and clamp shown in FIGS. 18 and 19 of the
drawings. As seen in these drawings, a window 71 already fitted in
a rectangular metallic window frame 72 is clamped between a pair of
window form-clamp components 73 and 74. The components 73, 74 are
both of inverted V-shape. The component 74 has an upwardly tilted,
limb 75 and a pair of vertical limbs 76, the outer edges of the
limbs 75 and 76 being curved so as to conform with the shape of the
flexible form to which it is to be attached. The component 73
consists of a substantially upwardly tilted limb 77 which
terminates in an upwardly directed flange 78 and substantially
vertical limbs 79 whose outer edges slope downwardly towards the
flexible form. The two components 74 and 73 are secured to each
other and to the metallic window frame 72 by means of straps 80
which are bolted to the adjacent components and the frame by means
of bolts 81, these bolts being removable from inside the window
form-clamp.
The window form-clamp together with the window rests on a precast
window sill 82, the latter being supported in the required position
against the flexible form by support means (not shown).
Cementitious or plastic material is applied to the flexible form
and to the window form-clamp so as to adopt the outer contour shown
by the broken line 83. When the cementitious or plastic material
has set and the flexible form removed, the form-clamp components 73
and 74 (which can be made, for example, of suitable fiber glass
material) can be detached by removal of the bolts 81. The component
73 can be removed from the outside of the shell whilst the
component 74 can be removed from the inside of the shell. Thus, the
window 71 and its frame 72 are left firmly set in the wall of the
shell within an appropriate window niche. If desired the form-clamp
components can be left in position. Where, however, the form-clamp
components are removed they can be reused on further occasions.
In the embodiment show in FIGS. 20, 21 and 22 of the drawings, a
simplified and modified form of base structure is employed. With
this base structure an annular concrete base ring 85 is
preliminarily cast and, if desired, is anchored in the ground.
Embedded in and projecting upwardly from the concrete ring 85 and
equiangularly spaced around the ring 85 are mounting posts 86. The
concrete base ring 85, when being cast is provided with
through-going bores 87 through which tensioning cables 88 are
arranged to pass. As shown in the drawings the through-going bore
87 as well as the upper surface of the concrete ring 85 slope
slightly upwardly in a direction away from the center of the ring.
Coupled to the mounting posts 86 is a form clamping structure 89
which consists of a plurality of annular segments 90 and a
plurality of clamping elements 91 having the characteristic
questionmark profile referred to above. The segments 90 and
clamping elements 91 are coupled together and to the mounting posts
86 by means of elongated bolts 92 which pass through the juxtaposed
elements and which are provided with tightening nuts 93 and
elongated sleeves 94.
The end of each tensioning cable 88 which emerges from the base
ring 85 is externally threaded and is provided with a nut 94a, a
steel washer 95 and a flexible washer 96. As seen in FIG. 22 of the
drawings, adjacent segments of the clamping mechanism 89 are
rigidly coupled together by means of pairs of coupling plates 97
and 98, the coupling plate 98 being formed integrally with an
elongated tubular sleeve 99. A coupling bolt 100 extends through
the coupling plates 97 and 98. Clamping of the two plates together
is effected by means of a nut 101 which, bearing against the end of
the sleeve 99, presses the two coupling plates 97 and 98 together,
thereby securing together the two elements 90 and 91 of the
clamping structure.
In operation, the rim of an inflatable form is clamped in the
clamping structure 89 in a manner as described above (ensuring the
required pretensioning of the form rim) and the clamping structure
itself is secured to the mounting posts 86 by tightening of the
clamping nuts 93. Successive segmental sections of the clamping
structure are rigidly secured together by tightening of the
clamping nuts 101 on the clamping bolts 100. The tensioning cables
88 are then given a predetermined degree of slackness by turning of
the nuts 94a and upon the inflation of the form, the cables 88 are
tensioned by the downwardly directed force on the form base. The
cementitious or other suitable material is then applied to the form
so as to form a shell 97. When this has set, loosening of the nut
93 results in the unclamping of the rim of the flexible form which
thereupon can be removed as can the clamping structure 89 and the
tensioning cables 88, the resulting concrete shell having been
formed on the concrete base ring 85.
Whilst in the embodiments described above the shell is formed on a
base ring which can, if desired, be anchored to an appropriate
foundation and which serves for anchoring the rim of the inflatable
form, there will now be described, with reference to FIG. 23 of the
drawings, an embodiment wherein the shell is formed on a base
structure which is entirely separate from the base ring, thereby
allowing the base ring to be removed together with the inflatable
form after the setting of the shell for reuse.
As seen in FIG. 23 an inflatable form 105 is anchored to a base
structure 106, the latter being of the kind described above, for
example, with reference to FIG. 3 of the drawings. The base ring
107 of the base structure 106 is supported on the jacks 108 by
virtue of which the base ring is raised sufficiently from off the
ground 109 to take account of the downward displacement of the
tensioning cables 110 and inner ring 111 upon inflation of the
form. The base structure 106 is located within a cylindrical wall
112 which can be constructed by conventional means and which, in
addition to any preformed apertures for doors etc., is provided
with apertures 113 by means of which access can be had to
tensioning nuts 114 located on the base ring 107 and by means of
which the slackness of the tensioning cables 110 can be adjusted to
a required level.
As can be seen from the drawing the wall 112 is sufficiently spaced
from the base ring 107 for the vertical wall to be directed
substantially tangentially to the inflated form 105 and so that the
layer of cementitious material 115 applied to the form 105
continues initially, substantially continuously from the
cylindrical wall 112. In other words the form must "swell" towards
the cylindrical wall.
This modification renders the process cheaper and faster to carry
out seeing that it is possible to retrieve and reuse the base
structures of the inflatable form whilst the use of jacks for
raising the base structure above the floor facilitates the use of
this method with floors which are preformed. The cylindrical wall
can be formed by any conventional method such as, for example, the
use of preformed segmental blocks.
Whilst in all the specific embodiments described above there has
been described a base structure having a base ring so constructed
as to be capable of withstanding the compressive forces arising out
of the tensioning of the tensioning cables, the present invention
is equally applicable in the case of a base structure having a base
ring constructed to be capable of withstanding the forces arising
out of compressing the cable.
FIGS. 24 and 25 of the drawings show schematically such a
modification. As seen in FIG. 24 a form 117 having a base 118 is
anchored to a base structure 119 consisting of a base ring 120 to
which are secured the ends of a plurality of radial compression
struts 121 whose inner ends are coupled at a central hub 122. As
seen in the drawing, upon inflation of the form 117 the base 118
thereof adopts a convex shape (as opposed to the concave shape
adopted by the base in all the previous embodiments) and this base
presses down on the compression struts 121 as a result of which
these struts press against the ring 120 which is in consequence
tensioned.
In the embodiment shown in FIG. 25 the struts 121 of the embodiment
shown in FIG. 24 are replaced by radial trusses 123 which also
serve to convert the downwardly directed forces acting thereon into
tensioning forces on ring 120.
The ring 120 which is made of metal can easily withstand such
tensioning forces and in consequence the forces which would
otherwise tend to lift the form are easily overcome without any
necessity for anchoring the base structure in the ground.
It will readily be seen that embodiments of the kind shown in FIGS.
24 and 25 enjoy the advantage that the base ring can be placed
directly on the ground there being no necessity for allowing for
the downward displacement of the tensioning cables.
It should be realized that the invention is not only applicable in
the case of construction of hemispherical domes or structures with
a circular peripheral shape but structures of other shapes can
equally well be constructed.
Finally, while the invention has been specifically described in
connection with the use of an inflatable form, on which, after
inflation a cementitious plastic material is applied and is allowed
to set, the invention is equally applicable in the case where the
form is used as a basis round which there is constructed, for
example, a geodesic construction. Alternatively the invention is
applicable in the case wherein the cementitious material is applied
to the form prior to its inflation and the form is subsequently
inflated and the material is allowed to set.
* * * * *