Title:
METHOD FOR MAKING SLAB-FACED AND HEADED PANELS INCLUDING CORNERS OR RETURNS
United States Patent 3694533
Abstract:
There is disclosed a system for top pouring and vertical pouring of concrete or other construction material composition panels faced on one side or both sides with slabs (including full brick) wherein each panel includes a corner or a return at least partly faced with slabs. The casting is accomplished in a special, angulated casting box having the surfaces where slabs are to be located covered with vacuum plate inserts which are, in effect, combined resilient gaskets for preventing backing composition soilage of slab faces and means for holding slabs against the mold as the mold is moved or disposed to facilitate backing composition pouring.
US Patent References:
Method of producing tile panels
Johnson - December 1967 - 3359354
Apparatus for making tile panels
Kastenbein - October 1958 - 2855653
Construction of hollow articles in reinforced concrete
Holter - September 1947 - 2427604
Method of producing tile panels
Johnson - December 1967 - 3359354
Apparatus for making tile panels
Kastenbein - October 1958 - 2855653
Construction of hollow articles in reinforced concrete
Holter - September 1947 - 2427604
Application Number:
05/049148
Publication Date:
09/26/1972
Filing Date:
06/23/1970
View Patent Images:
Export Citation:
Primary Class:
Other Classes:
425/123, 264/261, 264/277, 425/453, 264/256
International Classes:
B28B7/00; B28B7/08; B28B19/00; B32B31/06
Field of Search:
264/256,261,90 25/1B-D,2,41L
Primary Examiner:
White, Robert F.
Assistant Examiner:
Sokal, Allen M.
Claims:
What is claimed is
1. A process for manufacturing slab-faced panels which include corners, comprising:
2. The process of claim 1 comprising the additional steps of:
3. The process of claim 2 comprising the additional steps of:
4. The process of claim 3 wherein at least some of said slabs are arrayed in a simulation of staggered courses and wherein at least some of said slabs are L-shaped, so that conducting each of steps (e), (e') and (e") includes inserting at least one L-shaped slab in an L-shaped cell having front faces simultaneously on two of said covered surfaces, and so that conducting each of steps (f), (f') and (f") includes pushing each such L-shaped slab upon both rear faces thereof, against the resilient gasketing material on the two respective ones of said covered surfaces.
5. The process of claim 1 comprising the additional steps of:
6. A process for manufacturing slab-faced panels which include corners, comprising:
1. A process for manufacturing slab-faced panels which include corners, comprising:
2. The process of claim 1 comprising the additional steps of:
3. The process of claim 2 comprising the additional steps of:
4. The process of claim 3 wherein at least some of said slabs are arrayed in a simulation of staggered courses and wherein at least some of said slabs are L-shaped, so that conducting each of steps (e), (e') and (e") includes inserting at least one L-shaped slab in an L-shaped cell having front faces simultaneously on two of said covered surfaces, and so that conducting each of steps (f), (f') and (f") includes pushing each such L-shaped slab upon both rear faces thereof, against the resilient gasketing material on the two respective ones of said covered surfaces.
5. The process of claim 1 comprising the additional steps of:
6. A process for manufacturing slab-faced panels which include corners, comprising:
Description:
BACKGROUND OF THE INVENTION
In my co-pending U. S. Pat. application, Ser. No.49152, filed June 23, 1970, the background of slab-faced panel casting systems is disclosed in detail. Reference to the discussion there is recommended, that application also discloses a panel casting system wherein a casting box having at least one vacuum line connection through its floor is provided with a laminated insert plate which includes a resilient upper layer provided with one vacuum line opening for each slab, and which incorporates conduits extending from the openings to communication with the casting box floor. A placement grid having individual cells for receiving individual slabs is received in the casting box on the insert plate upper layer. After a slab has been placed in each cell, a heavy seater is lowered onto the slabs to force them into sealing contact with the insert plate resilient upper layer and a vacuum is drawn through the casting box floor to hold the slabs so tightly against the insert plate resilient upper layer that the layer bulges up between adjacent slabs. The seater is removed with the assistance of removable lateral shims and a settable composition such as concrete is poured into the casting box upon the slabs. The panels so formed have slabs set therein with simulated semi-flush concave joints. A modified device for production of panels faced with slabs on both sides is also disclosed.
Corners and returns have consistently presented a problem for those who would wish to entirely industrialize the production of slab-faced masonry walls. Even plain square or rectangular buildings have four corners, more complex perimetrical shapes often necessitated by building lot shapes or dictated by architectural considerations result in more corners, some of which may be acute or oblique, rather than being simple, right angle corners.
A "return" results where an exposed window or door casing or the like is not brought out flush with the straight-away wall portion it is included in.
In normal hand laid brick structures, "corners" and exposed areas at windows and doors give a most pleasing appearance because there is no vertical line break off or demarcation line. The normal "bond" and its jointwork follow around corners in a very pleasing manner - one that not only is pleasant to look at, but also one that indicates strength through the "tie ins", or really, the "lap ins" achieved. In such construction, the brick at the corners or returns each have a face exposed on one wall and a head (i.e. an end) exposed on the other wall.
Sometimes, even in hand laid brick structures, bricklayers or those who direct the work, will out of expediency or a willingness to accept less than what a craftsman would know to be right dispense with normal corner bonding and instead produce a break at the corner characterized by a straight, vertical mortar joint. Obviously, this is more than aesthetically displeasing; it is structurally weaker since the two walls are not tied together with intercalated brickwork. Similar expediency leads builders to cover over brickwork with wooden millwork around doors and windows where half or full returns would be more aesthetically pleasing.
Most precast slab-faced panel system developers appear to have thrown up their hands on the question or how to produce normal corner bonding and the appearance of well executed returns and reveals.
SUMMARY OF THE INVENTION
There is disclosed a system for top pouring and vertical pouring of concrete or other construction material composition panels faced on one side or both sides with slabs (including full brick) wherein each panel includes a corner or a return at least partly faced with slabs. The casting is accomplished in a special, angulated casting box having the surfaces where slabs are to be located covered with vacuum plate inserts which are, in effect, combined resilient gaskets for preventing backing composition soilage of slab faces and means for holding slabs against the mold as the mold is moved or disposed to facilitate backing composition pouring.
By utilizing a tiltable combination, horizontal and vertical vacuum casting table, that has special vacuum pads on both faces adjacent to the corner line, and by making two spaced pours, one can duplicate the jointwork attained in normal hand laid brick corners. By incorporating special vacuum inserts adjacent to end or side channels, one can duplicate the jointwork achieved with hand laid brick at door and window opening returns as well as exposed indented joints sometimes effectively used between adjacent precast panels.
With the addition of a base plate and a splitting of the mold, a very practical assembly is provided for casting all faced corner units vertically.
The principles of the invention will be further hereinafter discussed with reference to the drawings wherein preferred embodiments are shown. The specifics illustrated in the drawings are intended to exemplify, rather than limit, aspects of the invention as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a vertical, transverse sectional view of an angular casting box lined with vacuum plate inserts, coursed slabs and after completion of the first of two pours of backing composition;
FIG. 2 is a left-half side elevation of the apparatus and partly completed product of FIG. 1;
FIG. 3 is a perspective view of a panel produced in the apparatus of FIG. 1;
FIG. 3A is the projection of one end of the panel of FIG. 3 showing a half return;
FIG. 3B is the projection of another end of the panel of FIG. 3 showing a full return;
FIG. 4 is a horizontal, transverse sectional view of a modified angular casting box designed to produce angular panels faced interiorly and exteriorly with slabs and shown lined with slabs and ready to have backing composition poured thereinto;
FIG. 5 is a perspective view of a panel produced in the apparatus of FIG. 4; and
FIGS. 5A, 5B, 5C and 5D are projections of respective surfaces of the panel of FIG. 5.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
The term "slabs" is used generically herein to include blocks of brick, thin brick, slate and similar construction materials. Unless otherwise indicated, dimensions are given by way of example.
The casting box 10 of FIGS. 1 and 2 includes a first base plate 12 and a second base plate 14 which adjoins the first at an included angle of other than 180 degrees. In the instance depicted, the second base plate adjoins the first somewhat to the left of the right edge thereof. A channel brace 16 is welded or otherwise secured to the protruding right marginal portion of the first base plate and to the outside of the second base plate. Several other channel braces 18 are welded or otherwise secured to the outsides of the first and second base plates to provide support and resistance to buckling for the casting box base plates.
During use of the FIGS. 1 and 2 embodiment of the casting box in a horizontal position, it is necessary to rotate the casting box from a condition wherein the first base plate 12 is horizontal to another condition wherein the second base plate 14 is horizontal. To facilitate this, the casting box 10 is provided with two axially spaced circularly curved rockers 20, shown equipped with flat, circularly curved runners 22 adapted to support the casting box 10 on a surface. The runners extend sufficiently in a circumferential extent to allow the casting box to be moved between the two above-mentioned conditions.
The casting box 10 further includes two L-shaped end walls 24 of opposite ends of the casting box. The two legs 26, 28 of each end wall 24 respectively provide up-standing end walls for the two base plates 12 and 14 and may be defined by channel members. The casting box sides are shown completed by a channel member 30 extending between the outer ends of the two walls 26 and another channel member 32 extending between the outer ends of the two walls 28. As shown, the inside surfaces of the walls 26, 28, 30 and 32 are all flat.
Each of the walls 30 and 32 and the base plates 12 and 14 have openings 34 therethrough for application of vacuum to hold slabs against the interior of the mold. Suitable vacuum lines 36 connected to the openings 34 exteriorly of the casting box are communicated to a source of suction, e.g. a vacuum pump. Shut off valves 38 are interposed in the vacuum lines 36 in each branch to permit isolation of communication of suction to the several openings 34. The interior of the casting box 10 is shown provided with vacuum plate inserts 40A, 40B, 40C and 40D respectively having the first base plate 12, the second base plate 14, the sidewall 30 and the sidewall 32.
Each of the vacuum plate inserts (collectively referred to by the numeral 40) includes an outer layer 42 of closed cell foam rubber or like resilient material, an intermediate layer of stiffer material such as plywood or steel plate 44 and an inner liner 46 of closed cell foam rubber or like resilient material. The layers 42, 44 and 46 are provided with interconnecting openings 48 positioned to communicate the vacuum openings 34 with each site on the inner face 50 where a slab is to be held positioned by vacuum. The preferred shape of the openings 48 is as depicted and explained in my above-mentioned copending U. S. Pat. application.
The layers of the vacuum plate inserts are secured to one another, for instance, with suitable adhesive.
Fillers 52 of square cross section are secured in the three corners of the casting box where edges of two vacuum plate inserts 40 adjoin one another so that one insert 40 does not have to slip behind an edge of another and so that the corners are occupied.
As depicted, the vacuum plate insert 40D extends only part way up the wall 30 (i.e. the length of a brick head). The remainder of the wall 30 is covered by a spacer 54 whose thickness equals that of the vacuum plate insert when the latter is compressed.
The casting box 10 is prepared for casting by cleaning and oiling its interior metal surfaces, installing the vacuum plate inserts as shown. If necessary, the vacuum plate inserts may be maintained in place by means such as removable pins 56 projecting inwardly through the end walls 24 into slots in the corresponding edges of the intermediate layers 44 of the vacuum plate inserts. The slots are slightly elongated in such sense as to maintain the respective inner liner 46 abutting the respective casting box surface when the vacuum is off, but allow the respective vacuum plate insert to compress toward the respective casting box surface when the vacuum is turned on.
Next the casting box containing the emplaced vacuum plate inserts is lined with slabs S, each slab covering an outlet of an opening 48. By preference, as shown each slab S which has a head H against one vacuum plate insert and a face F against another vacuum plate insert covers an outlet of an opening 48 on each respective vacuum plate insert. Placement grids are preferably used to locate the slabs as described in my above-mentioned copending application. When all of the slabs S covering openings 48, 34 in one branch of the lines 36 are properly located and pressed against their respective vacuum plate inserts, the corresponding shut off valve 38 is opened and the slabs seated against the respective vacuum plate insert. This results in gasketing of the insert against the casting box, gasketing of the insert against the slabs which cover it, some resilient compression of the linings 42 and 46 of the vacuum plate insert and some bulging of the liner 46 up between adjacent slabs.
Openings 34 covered by spacers 54 may have their respective shut-off valves 38 left closed.
When all of the slabs have been positioned in this manner and the casting box positioned as shown in FIG. 1, fluid, settable backing composition, such as mortar M may be poured into the casting box and screeded level with the upper edges of the walls 30 and 26. After this composition has set sufficiently, the casting box 10 is rocked about a horizontal axis on the rockers 20, 22 until the vacuum plate insert 40B is disposed horizontally. Then a second quantum of backing composition is introduced into the casting box and screeded level with the upper edges of the walls 32 and 28. It should be noted that the bulging of the liner 46 between adjacent slabs causes a desirable semi-flush concave joint simulation to be created between adjacent slab faces. When the backing composition has set, the vacuum is turned off by closing the valves 38 or their master 58, the casting box is partly disassembled, for instance by removing one or more of the sidewalls 30, 32 and the completed panel P is removed from the casting box. As shown in FIGS. 3, 3A and 3B, the exemplary panel P formed in the casting box 10 has two outside surfaces faced with brick slabs S in what appears to be normal coursing; a half return is provided on the wall edge depicted in FIG. 3A and a full return is provided on the wall edge depicted in FIG. 3B. The included angle of the corner panel P depicted is 90 degrees and the two interior surfaces of the panel are plain and unfaced in the example.
The use of an open topped mold on rockers maximizes access to the interior of the casting box and makes less disassembly necessary for permitting removal of completed panels.
However, it should be apparent that the mold shown horizontally in FIG. 1 could be used vertically provided vertical sidewalls extending up toward the viewer were provided at the edges 60 and 62 meeting one another at the corner 64 and extending to connection with the channels 30 and 32. Such additional sidewalls would require bracing such as the channel bracing provided for the first and second base plates 12, 14. The uppermost end wall 24 would have to be provided with an opening or preferably eliminated, to permit pouring of backing composition B into the casting box. Very succinctly, the changes mentioned in the foregoing paragraph and a few further modifications constitute what is depicted in FIG. 4.
In the embodiment of FIG. 4 which is capable of producing the panel P2 of FIGS. 5 and 5A-5D, the changes just outlined are supplemented by provisions for greater disassembly of the casting box, of a stronger bottom wall and of added vacuum plate inserts disposed against the two added aforementioned walls.
The corresponding elements between the embodiments of FIGS. 1 and 4 have been given the same numerals. The differences apparent in the FIG. 4 embodiment are as follows:
1. The casting box is sitting upright and the viewer is looking downwardly into it. Thus, what would be an upper end wall has been eliminated in order to create an open top mold.
2. The opposite, lower end wall 24 has been expanded from L-shape by the inclusion of a strengthening triangular web 66.
3. The extra walls 68, 70 have been provided to complete the inner sides of the mold as outlined above and these have been lined with vacuum plate inserts 40E and 40F. The walls 30 and 32 have each been divided into two portions 30A, 30B and 32A, 32B and their covering vacuum plate inserts have likewise each been divided into two portions 40C1, 40C2 and 40D1, 40D2.
This permits ease of assembly and disassembly of the mold, since, in assembly, the walls 30A, 12, 14 and 32A may be bolted to one another and to the bottom base plate 24 as shown at 72, as a first assembly, and the walls 30B, 68, 70 and 32B may be secured to one another as shown, as a second assembly. After the two assemblies have been cleaned, oiled, vacuum plate inserts respectively installed, slabs S emplaced, seated and vacuum applied to maintain them in place through the lines 36, the two assemblies may be bolted together at 74.
As a review, it should be noted that the mold of the preferred embodiment of FIG. 4 may contain eight vacuum plate inserts: 40A, 40B, 40C1, 40C2, 40D1, 40D2, 40E and 40F. Actually, in the embodiment depicted, the insert 40D2 is a spacer substantially identical to the spacer 56 of FIG. 1 in order to produce the special wall ending depicted in FIG. 5A.
The mold is depicted in FIG. 4 with all of the slabs S in place, vacuum communicated to all of the vacuum plate inserts and ready for acceptance of a pour of backing composition.
To back track slightly, a use of the mold as depicted in FIG. 4 to produce a mortar backed panel faced on all sides with brick or brick slabs will now be discussed in detail in order to more clearly exemplify certain aspects of the invention.
In the following discussion, the individual casting box walls or pairs of walls having respective vacuum plate inserts bolted to them will be referred to as "sub assemblies " in accordance with the following schedule:
Sub Assembly Casting Box Wall(s) Vacuum Plate Insert(s) ____________________________________________________________ ______________ A 68, 70 40E, 40F B 32B 40C2 C 30B 40D2 D 12, 14 40A, 40B E 32A 40C1 F 30A 40D1 ____________________________________________________________ ______________
it is assumed that the sub assemblies and the bottom plate which make up the vertical pour casting box of FIG. 4 have been individually cleaned and oiled.
Step 1
A. rest sub assembly A on horses, (not shown), of suitable height so that its securely bolted in place vacuum plate inserts are face up.
B. bolt in place beside the vacuum plate inserts two temporary 2 1/2 inches × 2 1/4 inches × 1/4 inch angle irons which are to both complement and help hold in correct position their respective slab locating placement grids, (not shown, but of the same general design as are fully discussed in my aforementioned co-pending U. S. Pat. application).
C. position the locating grid for vacuum plate insert 40F.
D. fill that locating grid with required 1 inch thick half slabs S1, special 1 inch thick slabs 8 3/4 inches long S2, half corner split brick S3 or full corner split brick S4 as required. Each slab or corner split brick is to be individually hand seated and individually vacuum gripped.
E. remove the locating grid from vacuum plate insert 40F and its complementary supporting angle iron.
F. duplicate above procedures with vacuum plate insert 40E.
STEP 2
A. position sub assembly B and vacuum grip to it adjacent half and full corner split brick headers as shown in FIG. 4.
B. bolt sub assembly B to sub assembly A.
C. proceed in the same manner with sub assembly C.
STEP 3
A. bolt bottom plate 24 to sub assembly D.
B. position sub assembly D in a horizontal position and so that the surface to which vacuum plate insert 40B is secured is horizontal and vacuum plate insert A is secured to that main surface which is vertical.
C. bolt in place two temporary 2 1/2 inches × 2 1/2 inches × 1/4 inch angle irons, which are to both complement and help hold in position their respective locating grids.
D. position a locating grid upon vacuum plate insert 40B.
E. fill the locating grid with appropriate 1 inch thick half S1 or full slabs S4 and half S3 or full S4 corner split brick, hand setting and individually vacuum gripping each one. Where a split corner brick has two faces in contact with vacuum pad inserts, the vacuum is to be applied to the header face H first and to the stretcher face F last.
F. remove the locating grid and its complementary supporting angle iron.
STEP 4
A. rotate main rocker casting box frame (i.e. sub assembly B) 90 degrees, thus bringing vacuum plate insert 40A to a horizontal position and vacuum plate insert 40B to a vertical position.
B. proceed to place a locating grid on vacuum plate insert 40A in its correct position and then place in its cells the appropriate slabs or brick as was done on vacuum plate insert 40B.
C. seat the slabs and brick and apply vacuum.
D. remove the supporting angle iron and locating grid from vacuum plate insert 40A.
STEP 5
A. position sub assembly E and vacuum grip adjacent half and full corner split brick headers to it.
B. bolt sub assembly E down to sub assembly D.
C. proceed in the same manner with sub assembly F.
STEP 6
A. lower sub assembly A with its complement of vacuum gripped brick and brick slabs and installed sub assemblies B and C into position onto sub assembly D and its complement of brick and brick slabs and attached sub assemblies E and F. Coaxial bolt holes in adjacent sub assemblies E and B as well as in adjacent sub assemblies C and F allow these two major assemblies to be bolted together. Like coaxial matching bolt holes at this time allow the bolting of sub assemblies F, C, B and E directly to the bottom base plate 24.
STEP 7
A. while continuing to maintain vacuum, the fully assembled and completely faced casting box is lifted into a vertical position on its bottom plate, i.e. to the position shown in FIG. 4.
STEP 8
A. pour the casting box full of fairly soft consistancy mortar or other fluid, settable backing composition at a slow even rate while maintaining moderate internal vibration.
B. screed off top and imbed heavy duty lifting core with attached reinforcing rods into casting at its approximate geometric center.
C. keep vacuum on until mortar is quite hard and form removal is in process.
STEP 9
A. release vacuum from all branches of line 36.
B. remove bolts holding sub assembly A to sub assemblies B and C.
C. lift off sub assembly A.
D. remove sub assemblies B and E from sub assembly D and base plate 24 after removing necessary bolts.
E. remove, in the same manner, sub assemblies C and F from sub assembly D and base plate 24.
F. at this point with some types of facings the completed corner unit (the panel of FIG. 5) can be safely freed from the remaining casting box and removed to storage. However, certain facing materials may not permit safe removal at this stage without the introduction of high pressure air into that part of the vacuum piping which still leads to areas where there is still contact between facing units and the vacuum plate inserts' surfaces. There may be an individual or a few facings that will not "break loose" even with the air treatment. In such cases, it may be necessary to further dismantle the casting box. The whole assembly backing up vacuum plate insert 40B can be removed by removing a few more bolts. Likewise even the base plate can be detached. With contact only left between the casting and vacuum plate insert 40A, there can be no further removal difficulty. The built-in disassembly provisions just described are provided to make it possible to safely remove castings regardless of how tough or penetrating their facings may be.
It should be apparent that the casting boxes have been shown having right angle corners since right angle cornered panels are obviously in most demand; casting boxes having different included angles do not differ in principle from the two just discussed. It should also be appreciated that many other kinds and arrangements of facings can be provided than those depicted and that by substituting spacers 54 for any vacuum plate inserts, the desired panel surfaces or parts thereof can be left unfaced.
It should now be apparent that the slab-faced and headed panels including corners or returns as described herein above possesses each of the attributes set forth in the specification under the heading "Summary of the Invention" hereinbefore. Because the slab-faced and headed panels including corners or returns of the invention can be modified to some extent without departing from the principles of the invention as they have been outlined and explained in this specification, the present invention should be understood as encompassing all such modifications as are within the spirit and scope of the following claims.
In my co-pending U. S. Pat. application, Ser. No.49152, filed June 23, 1970, the background of slab-faced panel casting systems is disclosed in detail. Reference to the discussion there is recommended, that application also discloses a panel casting system wherein a casting box having at least one vacuum line connection through its floor is provided with a laminated insert plate which includes a resilient upper layer provided with one vacuum line opening for each slab, and which incorporates conduits extending from the openings to communication with the casting box floor. A placement grid having individual cells for receiving individual slabs is received in the casting box on the insert plate upper layer. After a slab has been placed in each cell, a heavy seater is lowered onto the slabs to force them into sealing contact with the insert plate resilient upper layer and a vacuum is drawn through the casting box floor to hold the slabs so tightly against the insert plate resilient upper layer that the layer bulges up between adjacent slabs. The seater is removed with the assistance of removable lateral shims and a settable composition such as concrete is poured into the casting box upon the slabs. The panels so formed have slabs set therein with simulated semi-flush concave joints. A modified device for production of panels faced with slabs on both sides is also disclosed.
Corners and returns have consistently presented a problem for those who would wish to entirely industrialize the production of slab-faced masonry walls. Even plain square or rectangular buildings have four corners, more complex perimetrical shapes often necessitated by building lot shapes or dictated by architectural considerations result in more corners, some of which may be acute or oblique, rather than being simple, right angle corners.
A "return" results where an exposed window or door casing or the like is not brought out flush with the straight-away wall portion it is included in.
In normal hand laid brick structures, "corners" and exposed areas at windows and doors give a most pleasing appearance because there is no vertical line break off or demarcation line. The normal "bond" and its jointwork follow around corners in a very pleasing manner - one that not only is pleasant to look at, but also one that indicates strength through the "tie ins", or really, the "lap ins" achieved. In such construction, the brick at the corners or returns each have a face exposed on one wall and a head (i.e. an end) exposed on the other wall.
Sometimes, even in hand laid brick structures, bricklayers or those who direct the work, will out of expediency or a willingness to accept less than what a craftsman would know to be right dispense with normal corner bonding and instead produce a break at the corner characterized by a straight, vertical mortar joint. Obviously, this is more than aesthetically displeasing; it is structurally weaker since the two walls are not tied together with intercalated brickwork. Similar expediency leads builders to cover over brickwork with wooden millwork around doors and windows where half or full returns would be more aesthetically pleasing.
Most precast slab-faced panel system developers appear to have thrown up their hands on the question or how to produce normal corner bonding and the appearance of well executed returns and reveals.
SUMMARY OF THE INVENTION
There is disclosed a system for top pouring and vertical pouring of concrete or other construction material composition panels faced on one side or both sides with slabs (including full brick) wherein each panel includes a corner or a return at least partly faced with slabs. The casting is accomplished in a special, angulated casting box having the surfaces where slabs are to be located covered with vacuum plate inserts which are, in effect, combined resilient gaskets for preventing backing composition soilage of slab faces and means for holding slabs against the mold as the mold is moved or disposed to facilitate backing composition pouring.
By utilizing a tiltable combination, horizontal and vertical vacuum casting table, that has special vacuum pads on both faces adjacent to the corner line, and by making two spaced pours, one can duplicate the jointwork attained in normal hand laid brick corners. By incorporating special vacuum inserts adjacent to end or side channels, one can duplicate the jointwork achieved with hand laid brick at door and window opening returns as well as exposed indented joints sometimes effectively used between adjacent precast panels.
With the addition of a base plate and a splitting of the mold, a very practical assembly is provided for casting all faced corner units vertically.
The principles of the invention will be further hereinafter discussed with reference to the drawings wherein preferred embodiments are shown. The specifics illustrated in the drawings are intended to exemplify, rather than limit, aspects of the invention as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a vertical, transverse sectional view of an angular casting box lined with vacuum plate inserts, coursed slabs and after completion of the first of two pours of backing composition;
FIG. 2 is a left-half side elevation of the apparatus and partly completed product of FIG. 1;
FIG. 3 is a perspective view of a panel produced in the apparatus of FIG. 1;
FIG. 3A is the projection of one end of the panel of FIG. 3 showing a half return;
FIG. 3B is the projection of another end of the panel of FIG. 3 showing a full return;
FIG. 4 is a horizontal, transverse sectional view of a modified angular casting box designed to produce angular panels faced interiorly and exteriorly with slabs and shown lined with slabs and ready to have backing composition poured thereinto;
FIG. 5 is a perspective view of a panel produced in the apparatus of FIG. 4; and
FIGS. 5A, 5B, 5C and 5D are projections of respective surfaces of the panel of FIG. 5.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
The term "slabs" is used generically herein to include blocks of brick, thin brick, slate and similar construction materials. Unless otherwise indicated, dimensions are given by way of example.
The casting box 10 of FIGS. 1 and 2 includes a first base plate 12 and a second base plate 14 which adjoins the first at an included angle of other than 180 degrees. In the instance depicted, the second base plate adjoins the first somewhat to the left of the right edge thereof. A channel brace 16 is welded or otherwise secured to the protruding right marginal portion of the first base plate and to the outside of the second base plate. Several other channel braces 18 are welded or otherwise secured to the outsides of the first and second base plates to provide support and resistance to buckling for the casting box base plates.
During use of the FIGS. 1 and 2 embodiment of the casting box in a horizontal position, it is necessary to rotate the casting box from a condition wherein the first base plate 12 is horizontal to another condition wherein the second base plate 14 is horizontal. To facilitate this, the casting box 10 is provided with two axially spaced circularly curved rockers 20, shown equipped with flat, circularly curved runners 22 adapted to support the casting box 10 on a surface. The runners extend sufficiently in a circumferential extent to allow the casting box to be moved between the two above-mentioned conditions.
The casting box 10 further includes two L-shaped end walls 24 of opposite ends of the casting box. The two legs 26, 28 of each end wall 24 respectively provide up-standing end walls for the two base plates 12 and 14 and may be defined by channel members. The casting box sides are shown completed by a channel member 30 extending between the outer ends of the two walls 26 and another channel member 32 extending between the outer ends of the two walls 28. As shown, the inside surfaces of the walls 26, 28, 30 and 32 are all flat.
Each of the walls 30 and 32 and the base plates 12 and 14 have openings 34 therethrough for application of vacuum to hold slabs against the interior of the mold. Suitable vacuum lines 36 connected to the openings 34 exteriorly of the casting box are communicated to a source of suction, e.g. a vacuum pump. Shut off valves 38 are interposed in the vacuum lines 36 in each branch to permit isolation of communication of suction to the several openings 34. The interior of the casting box 10 is shown provided with vacuum plate inserts 40A, 40B, 40C and 40D respectively having the first base plate 12, the second base plate 14, the sidewall 30 and the sidewall 32.
Each of the vacuum plate inserts (collectively referred to by the numeral 40) includes an outer layer 42 of closed cell foam rubber or like resilient material, an intermediate layer of stiffer material such as plywood or steel plate 44 and an inner liner 46 of closed cell foam rubber or like resilient material. The layers 42, 44 and 46 are provided with interconnecting openings 48 positioned to communicate the vacuum openings 34 with each site on the inner face 50 where a slab is to be held positioned by vacuum. The preferred shape of the openings 48 is as depicted and explained in my above-mentioned copending U. S. Pat. application.
The layers of the vacuum plate inserts are secured to one another, for instance, with suitable adhesive.
Fillers 52 of square cross section are secured in the three corners of the casting box where edges of two vacuum plate inserts 40 adjoin one another so that one insert 40 does not have to slip behind an edge of another and so that the corners are occupied.
As depicted, the vacuum plate insert 40D extends only part way up the wall 30 (i.e. the length of a brick head). The remainder of the wall 30 is covered by a spacer 54 whose thickness equals that of the vacuum plate insert when the latter is compressed.
The casting box 10 is prepared for casting by cleaning and oiling its interior metal surfaces, installing the vacuum plate inserts as shown. If necessary, the vacuum plate inserts may be maintained in place by means such as removable pins 56 projecting inwardly through the end walls 24 into slots in the corresponding edges of the intermediate layers 44 of the vacuum plate inserts. The slots are slightly elongated in such sense as to maintain the respective inner liner 46 abutting the respective casting box surface when the vacuum is off, but allow the respective vacuum plate insert to compress toward the respective casting box surface when the vacuum is turned on.
Next the casting box containing the emplaced vacuum plate inserts is lined with slabs S, each slab covering an outlet of an opening 48. By preference, as shown each slab S which has a head H against one vacuum plate insert and a face F against another vacuum plate insert covers an outlet of an opening 48 on each respective vacuum plate insert. Placement grids are preferably used to locate the slabs as described in my above-mentioned copending application. When all of the slabs S covering openings 48, 34 in one branch of the lines 36 are properly located and pressed against their respective vacuum plate inserts, the corresponding shut off valve 38 is opened and the slabs seated against the respective vacuum plate insert. This results in gasketing of the insert against the casting box, gasketing of the insert against the slabs which cover it, some resilient compression of the linings 42 and 46 of the vacuum plate insert and some bulging of the liner 46 up between adjacent slabs.
Openings 34 covered by spacers 54 may have their respective shut-off valves 38 left closed.
When all of the slabs have been positioned in this manner and the casting box positioned as shown in FIG. 1, fluid, settable backing composition, such as mortar M may be poured into the casting box and screeded level with the upper edges of the walls 30 and 26. After this composition has set sufficiently, the casting box 10 is rocked about a horizontal axis on the rockers 20, 22 until the vacuum plate insert 40B is disposed horizontally. Then a second quantum of backing composition is introduced into the casting box and screeded level with the upper edges of the walls 32 and 28. It should be noted that the bulging of the liner 46 between adjacent slabs causes a desirable semi-flush concave joint simulation to be created between adjacent slab faces. When the backing composition has set, the vacuum is turned off by closing the valves 38 or their master 58, the casting box is partly disassembled, for instance by removing one or more of the sidewalls 30, 32 and the completed panel P is removed from the casting box. As shown in FIGS. 3, 3A and 3B, the exemplary panel P formed in the casting box 10 has two outside surfaces faced with brick slabs S in what appears to be normal coursing; a half return is provided on the wall edge depicted in FIG. 3A and a full return is provided on the wall edge depicted in FIG. 3B. The included angle of the corner panel P depicted is 90 degrees and the two interior surfaces of the panel are plain and unfaced in the example.
The use of an open topped mold on rockers maximizes access to the interior of the casting box and makes less disassembly necessary for permitting removal of completed panels.
However, it should be apparent that the mold shown horizontally in FIG. 1 could be used vertically provided vertical sidewalls extending up toward the viewer were provided at the edges 60 and 62 meeting one another at the corner 64 and extending to connection with the channels 30 and 32. Such additional sidewalls would require bracing such as the channel bracing provided for the first and second base plates 12, 14. The uppermost end wall 24 would have to be provided with an opening or preferably eliminated, to permit pouring of backing composition B into the casting box. Very succinctly, the changes mentioned in the foregoing paragraph and a few further modifications constitute what is depicted in FIG. 4.
In the embodiment of FIG. 4 which is capable of producing the panel P2 of FIGS. 5 and 5A-5D, the changes just outlined are supplemented by provisions for greater disassembly of the casting box, of a stronger bottom wall and of added vacuum plate inserts disposed against the two added aforementioned walls.
The corresponding elements between the embodiments of FIGS. 1 and 4 have been given the same numerals. The differences apparent in the FIG. 4 embodiment are as follows:
1. The casting box is sitting upright and the viewer is looking downwardly into it. Thus, what would be an upper end wall has been eliminated in order to create an open top mold.
2. The opposite, lower end wall 24 has been expanded from L-shape by the inclusion of a strengthening triangular web 66.
3. The extra walls 68, 70 have been provided to complete the inner sides of the mold as outlined above and these have been lined with vacuum plate inserts 40E and 40F. The walls 30 and 32 have each been divided into two portions 30A, 30B and 32A, 32B and their covering vacuum plate inserts have likewise each been divided into two portions 40C1, 40C2 and 40D1, 40D2.
This permits ease of assembly and disassembly of the mold, since, in assembly, the walls 30A, 12, 14 and 32A may be bolted to one another and to the bottom base plate 24 as shown at 72, as a first assembly, and the walls 30B, 68, 70 and 32B may be secured to one another as shown, as a second assembly. After the two assemblies have been cleaned, oiled, vacuum plate inserts respectively installed, slabs S emplaced, seated and vacuum applied to maintain them in place through the lines 36, the two assemblies may be bolted together at 74.
As a review, it should be noted that the mold of the preferred embodiment of FIG. 4 may contain eight vacuum plate inserts: 40A, 40B, 40C1, 40C2, 40D1, 40D2, 40E and 40F. Actually, in the embodiment depicted, the insert 40D2 is a spacer substantially identical to the spacer 56 of FIG. 1 in order to produce the special wall ending depicted in FIG. 5A.
The mold is depicted in FIG. 4 with all of the slabs S in place, vacuum communicated to all of the vacuum plate inserts and ready for acceptance of a pour of backing composition.
To back track slightly, a use of the mold as depicted in FIG. 4 to produce a mortar backed panel faced on all sides with brick or brick slabs will now be discussed in detail in order to more clearly exemplify certain aspects of the invention.
In the following discussion, the individual casting box walls or pairs of walls having respective vacuum plate inserts bolted to them will be referred to as "sub assemblies " in accordance with the following schedule:
Sub Assembly Casting Box Wall(s) Vacuum Plate Insert(s) ____________________________________________________________ ______________ A 68, 70 40E, 40F B 32B 40C2 C 30B 40D2 D 12, 14 40A, 40B E 32A 40C1 F 30A 40D1 ____________________________________________________________ ______________
it is assumed that the sub assemblies and the bottom plate which make up the vertical pour casting box of FIG. 4 have been individually cleaned and oiled.
Step 1
A. rest sub assembly A on horses, (not shown), of suitable height so that its securely bolted in place vacuum plate inserts are face up.
B. bolt in place beside the vacuum plate inserts two temporary 2 1/2 inches × 2 1/4 inches × 1/4 inch angle irons which are to both complement and help hold in correct position their respective slab locating placement grids, (not shown, but of the same general design as are fully discussed in my aforementioned co-pending U. S. Pat. application).
C. position the locating grid for vacuum plate insert 40F.
D. fill that locating grid with required 1 inch thick half slabs S1, special 1 inch thick slabs 8 3/4 inches long S2, half corner split brick S3 or full corner split brick S4 as required. Each slab or corner split brick is to be individually hand seated and individually vacuum gripped.
E. remove the locating grid from vacuum plate insert 40F and its complementary supporting angle iron.
F. duplicate above procedures with vacuum plate insert 40E.
STEP 2
A. position sub assembly B and vacuum grip to it adjacent half and full corner split brick headers as shown in FIG. 4.
B. bolt sub assembly B to sub assembly A.
C. proceed in the same manner with sub assembly C.
STEP 3
A. bolt bottom plate 24 to sub assembly D.
B. position sub assembly D in a horizontal position and so that the surface to which vacuum plate insert 40B is secured is horizontal and vacuum plate insert A is secured to that main surface which is vertical.
C. bolt in place two temporary 2 1/2 inches × 2 1/2 inches × 1/4 inch angle irons, which are to both complement and help hold in position their respective locating grids.
D. position a locating grid upon vacuum plate insert 40B.
E. fill the locating grid with appropriate 1 inch thick half S1 or full slabs S4 and half S3 or full S4 corner split brick, hand setting and individually vacuum gripping each one. Where a split corner brick has two faces in contact with vacuum pad inserts, the vacuum is to be applied to the header face H first and to the stretcher face F last.
F. remove the locating grid and its complementary supporting angle iron.
STEP 4
A. rotate main rocker casting box frame (i.e. sub assembly B) 90 degrees, thus bringing vacuum plate insert 40A to a horizontal position and vacuum plate insert 40B to a vertical position.
B. proceed to place a locating grid on vacuum plate insert 40A in its correct position and then place in its cells the appropriate slabs or brick as was done on vacuum plate insert 40B.
C. seat the slabs and brick and apply vacuum.
D. remove the supporting angle iron and locating grid from vacuum plate insert 40A.
STEP 5
A. position sub assembly E and vacuum grip adjacent half and full corner split brick headers to it.
B. bolt sub assembly E down to sub assembly D.
C. proceed in the same manner with sub assembly F.
STEP 6
A. lower sub assembly A with its complement of vacuum gripped brick and brick slabs and installed sub assemblies B and C into position onto sub assembly D and its complement of brick and brick slabs and attached sub assemblies E and F. Coaxial bolt holes in adjacent sub assemblies E and B as well as in adjacent sub assemblies C and F allow these two major assemblies to be bolted together. Like coaxial matching bolt holes at this time allow the bolting of sub assemblies F, C, B and E directly to the bottom base plate 24.
STEP 7
A. while continuing to maintain vacuum, the fully assembled and completely faced casting box is lifted into a vertical position on its bottom plate, i.e. to the position shown in FIG. 4.
STEP 8
A. pour the casting box full of fairly soft consistancy mortar or other fluid, settable backing composition at a slow even rate while maintaining moderate internal vibration.
B. screed off top and imbed heavy duty lifting core with attached reinforcing rods into casting at its approximate geometric center.
C. keep vacuum on until mortar is quite hard and form removal is in process.
STEP 9
A. release vacuum from all branches of line 36.
B. remove bolts holding sub assembly A to sub assemblies B and C.
C. lift off sub assembly A.
D. remove sub assemblies B and E from sub assembly D and base plate 24 after removing necessary bolts.
E. remove, in the same manner, sub assemblies C and F from sub assembly D and base plate 24.
F. at this point with some types of facings the completed corner unit (the panel of FIG. 5) can be safely freed from the remaining casting box and removed to storage. However, certain facing materials may not permit safe removal at this stage without the introduction of high pressure air into that part of the vacuum piping which still leads to areas where there is still contact between facing units and the vacuum plate inserts' surfaces. There may be an individual or a few facings that will not "break loose" even with the air treatment. In such cases, it may be necessary to further dismantle the casting box. The whole assembly backing up vacuum plate insert 40B can be removed by removing a few more bolts. Likewise even the base plate can be detached. With contact only left between the casting and vacuum plate insert 40A, there can be no further removal difficulty. The built-in disassembly provisions just described are provided to make it possible to safely remove castings regardless of how tough or penetrating their facings may be.
It should be apparent that the casting boxes have been shown having right angle corners since right angle cornered panels are obviously in most demand; casting boxes having different included angles do not differ in principle from the two just discussed. It should also be appreciated that many other kinds and arrangements of facings can be provided than those depicted and that by substituting spacers 54 for any vacuum plate inserts, the desired panel surfaces or parts thereof can be left unfaced.
It should now be apparent that the slab-faced and headed panels including corners or returns as described herein above possesses each of the attributes set forth in the specification under the heading "Summary of the Invention" hereinbefore. Because the slab-faced and headed panels including corners or returns of the invention can be modified to some extent without departing from the principles of the invention as they have been outlined and explained in this specification, the present invention should be understood as encompassing all such modifications as are within the spirit and scope of the following claims.