WALL FORMING APPARATUS AND METHODS
A wall forming apparatus and methods having a series of walls that are movable to form molding compartments into which fluid concrete can be poured and allowed to harden to form a cement wall. Spacer members determine the width of the compartments and, accordingly, the thickness of the manufactured wall. Steel cables under tension maintain the integrity of the shape of the compartments when they are subjected to the pressure applied against the walls by the fluid concrete.
This application claims the benefit of U.S. Application 60/934,787 filed Jun. 15, 2007, the entire contents of which is expressly incorporated herein by reference.
FIELD OF THE INVENTIONThis invention relates to apparatus and methods for forming concrete walls and particularly for efficiently manufacturing a plurality of long concrete wall panels.
SUMMARY OF THE INVENTIONIn one embodiment, a plurality of concrete wall panels are manufactured in a panel forming apparatus providing a series of parallel hollow molding compartments. These compartments may be of varying length and width. Steel cables under tension maintain the integrity of the shape of each compartment when subjected to the extreme pressure applied against the walls of the compartment by the liquid concrete.
Steel rebar and mesh kits are supported within the compartments and concrete is then poured into each compartment. The poured concrete is vibrated by a ganged series of electrical vibrators to remove trapped air bubbles which would otherwise mar the attractive appearance of the finished wall panel.
After the poured concrete has set, the parallel compartments are opened and the concrete wall panels typically lifted from the panel forming apparatus by a crane.
The panel forming apparatus can include, as shown in the embodiment illustrated in
The size of the superstructure will typically be determined by the length of the concrete panels to be molded and allow sufficient room so that workers can have ready access between any two of the movable wall forming panels 125 described below.
Movable Wall Forming PanelsA plurality of movable wall forming panels 125 are movably supported inside the superstructure 100. In the embodiment shown in
As shown in
The top of each movable panel 125 and fixed wall 105 can be covered as shown in
The maximum length of each concrete section is determined by the length of the panel 125. The width (thickness) of each molded concrete panel is determined by the width of the spacer 165 placed between each of the panels 125 as shown in
The length of the cavity can also be varied to mold shorter panels by using panel blanks 167, 167′ of predetermined width as shown in
Accordingly, an aspect of the embodiment shown is that both the length and width of the manufactured concrete wall panels can be varied by use of spacers 165 (
The weight of the liquid concrete subjects the movable panels 125 to extreme pressure at their mid-length. Any structural deformation of a panel 125 will result in a defective molded concrete wall. Such forces have heretofore made it impractical to vertically mold very long panels of 14 feet or more from poured concrete.
In the embodiment shown, however, the tension system 175 maintains the integrity of the superstructure walls 105, 110 against bowing or distorting to thereby successfully oppose the very high pressures exerted upon the movable panel wall forms 125 when the cavities 160 are filled with wet concrete.
Tension system 175 can include, as shown in
In the embodiment shown, the tension supplied by cable 190 is adjusted by a turn screw apparatus on each strut 180. As shown in
Further, as shown in
The tension system 175 thus maintains a constant tension force on the midsection of walls 105, 110. These tension forces are transferred to the movable panels 125 after the panels 125 have been moved along tracks 135, 136 to set-up a plurality of molding compartment panels.
Texture or PatternThe concrete wall panels can be manufactured with a variety of textures or patterns by securing a liner to the face of the movable wall forming panel 125 and wall 126. This liner is typically a thin sheet of rubber or plastic the same size as the panel 125 and wall 126 having a pattern formed on its outer face which is the reverse image of the desired pattern on the concrete wall. In one embodiment, the rubber or plastic liner is attached to the supporting steel plate with a combination of screws and liquid nails placed primarily near the horizontal ends of the panel 125 so that any imprint of the screw on the molded concrete wall will be hidden inside a column erected when the fence is installed.
Safety PlatformsDuring molding of concrete fence panels, the workers on top of the superstructure 100 are 6 or more feet above ground. A safety device for these workers is provided by safety platform 250 having side rails 255 and attached, as shown in
Steel mesh and rebar is tied together to provide a rebar/mesh kit 260. Kit 260 is supported within each molding compartment 160 before concrete is poured. As shown in
The rebar/wire mesh kits 260 are respectively hung in approximately the center of each cavity 160. As shown in
The manufacture of concrete wall panels begins with moving panels 125 to open space for a worker between wall 126 and panel 125L. As shown in
Starting with the wall 126 on the inside of end 105 of superstructure 100, a textured or patterned liner may be attached (or a different one substituted for one already attached) to wall 126 and the facing wall of panel 125L. A release agent is then applied to all textured surfaces of wall 126 and the facing wall of panel 125L to prevent sticking of the concrete during extraction of a finished concrete wall panel.
A completed steel rebar/mesh kit 260, spacer 165 (and short panel blank 167 if used) are then located against wall 125. The rebar/mesh kit 260 is positioned to reach to or close to the floor 121.
A rubber sealing mat is laid at the bottom of each molding compartment 160 on floor 121 so that when the wall panels 125 are pushed together, the bottom of each wall 125 is sealed to prevent concrete from leaking out between the bottom of each panel 125 and floor plate 121.
The foregoing steps are repeated until all of the twelve compartments have been prepped. Once all of wall forming panels 125 have been pushed together to form the molding compartments 160, the first movable wall panel 125A is placed under stress by a series of horizontal anchor struts 295 shown in
In the embodiment shown, the anchor struts 295 each include turn screws so as to be adjustable in length and may, for example, be similar in function to the struts 180 described above. Thus, as a threaded lever 310 is turned to lengthen a strut 295, force is applied between the superstructure wall 110 and movable wall forming panel 125A. This force is resisted by tension system 175. As a result, the forces produced when liquid concrete is poured into the compartments 160 will be countered by the tension system 175.
On top of the superstructure 100, lifting lugs or hooks 380 are attached to a steel holding plate of 4 inch wide by 10 feet long and ⅛ inch thick. The holding plate has ¾ inch holes through which the threaded lifting lug bolt is inserted and threaded into the lifting lug component that will be encased in concrete.
Concrete is then pumped in the normal manner from a concrete truck and concrete pump through pipes or tubes to a trough 350 shown in
After vibration of the poured concrete has been completed, the entire top of each compartment 160 is scraped smooth so that the top of the concrete wall panels will be smooth.
After the concrete has set, the finished panels are extracted from the molding compartments 160. The anchor struts 295 (
Mobile Panel Forming Apparatus
A mobile panel forming apparatus 400 is shown in
The trailer mounted unit shown is designed to have a width no greater than 104″ so as to not require oversize road permits. In order to accommodate this width restriction, the unit 400 includes ten movable wall mounting panels 425.
After the mobile apparatus 400 is moved to an on-site location, stabilizers 430 are lowered to the ground and used to lift the trailer 410 and its tires 435 off the ground. As a result, the substantial weight of the concrete when poured into the wall panel molding compartments does not need to be supported by the tires 435.
Although the foregoing apparatus and methods have been described in terms of certain preferred embodiments, other embodiments will be apparent to those of ordinary skill in the art from the disclosure herein. Additionally, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of the disclosure herein. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms without departing from the spirit thereof. Accordingly, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of the disclosure herein.
Claims
1. A panel forming apparatus for manufacturing concrete wall panels, comprising:
- a superstructure having a first longitudinal side, a second longitudinal side, a proximal end side, and a distal end side, wherein said first and second longitudinal sides are attached to said proximal and distal end sides, said first and second longitudinal sides being substantially parallel and said proximal and distal end sides being substantially parallel, said superstructure being designed to withstand high pressures;
- a plurality of wall forming panels slidably positioned substantially parallel to said first longitudinal side and said second longitudinal side, said wall forming panels capable of moving in the space between said first and second longitudinal sides to form a plurality of parallel hollow wall molding compartments, said parallel hollow wall molding compartments capable of receiving fluid concrete that hardens or cures to form said wall panels;
- a plurality of spacer members forming opposite ends of said molding compartments to maintain a predetermined space between adjacent panels so that the thickness of the concrete panel is determined by the width of said spacer member;
- a sealing member at the bottom of each molding component to inhibit concrete leakage from the bottom of said compartments; and
- a tension system operable with said superstructure for maintaining the integrity of said first and second longitudinal sides of said superstructure, wherein said tension system comprises a tension wire cable capable of receiving a tensile force, and a tension cabling system, wherein said tension cabling system transfers said tensile force of said tension wire cable perpendicularly to the walls of said first and second longitudinal sides of said superstructure to maintain the integrity of said walls of said first and second longitudinal walls.
2. Apparatus for varying the longitudinal length of a wall panel fabricated by hardening or curing a solidifying a mixture in a hollow wall molding compartment, comprising:
- a substantially rectangular block of low density material shaped and configured to be inserted into said hollow wall molding compartment prior to said solidifying mixture being introduced into said hollow wall molding compartment, said rectangular block being inserted to occupy a portion of space in said hollow wall molding compartment such that when said solidifying mixture hardens or cures, the longitudinal length of said wall panel fabricated in said hollow wall molding compartment is less than a similar wall panel hardened or cured in said hollow wall molding compartment when said short panel jig is absent.
3. A panel forming apparatus for manufacturing wall panels, comprising:
- a superstructure being substantially rectangular in shape having a first longitudinal side, a second longitudinal side, a proximal end side, and a distal end side;
- and at least one wall forming panel positioned in the interior of said superstructure being substantially parallel to said proximal end side and said distal end side and capable of moving in the space between said first and second longitudinal sides to form at least one hollow wall molding compartment, said hollow wall molding compartment capable of receiving a solidifying mixture to form said wall panel;
4. The panel forming apparatus of claim 3, further comprising a tension system operable with said superstructure for maintaining the integrity of the walls of said first and second longitudinal sides, said tension system acting as a counter force to a force exerted by said solidifying mixture on said walls of said first and second longitudinal sides after said solidifying mixture is received in said parallel hollow wall molding compartments.
5. The panel forming apparatus of claim 4, wherein said tension system comprises a tension wire cable capable of receiving a tensile force, and a tension cabling system, wherein said counter force is created by said tension cabling system transferring said tensile force of said tension wire cable perpendicularly to said walls of said first and second longitudinal sides.
6. The panel forming apparatus of claim 5, wherein said tension system further comprises adjustable struts held perpendicular to said walls of said first and second longitudinal sides; a slotted receptacle for receiving said tension wire cable; and a screw apparatus, said screw apparatus functioning to adjust said tensile force of said tension wire cable by longitudinally lengthening or shortening said tension cabling system, wherein the lengthening or shortening of said tension cabling system functions to respectively stretch or relax said tension wire cable thereby adjusting said tensile force.
7. The panel forming apparatus of claim 4, wherein said tension system is maintained in a stable horizontal orientation orthogonal to one of said first or second longitudinal sides by attaching one end of a cable at a distal end of said tension system and attaching the other end of said cable to the said one of said first or second longitudinal sides.
8. The panel forming apparatus of claim 3, further comprising a short panel blank for varying the length of said wall panels, said short panel blank comprising a rectangular block of low density material configured to be inserted into at least one of said parallel hollow wall molding compartments to vary the length of said wall panels.
9. The panel forming apparatus of claim 3, wherein the width of said wall panels is determined by a spacer, said spacer being positioned between juxtaposed wall forming panels.
10. The panel forming apparatus of claim 3, wherein said solidifying mixture is comprised of cement and other materials such that said solidifying mixture hardens or cures to form concrete wall panels.
11. The panel forming apparatus of claim 10, wherein steel rebar is supported within said parallel hollow wall molding compartments prior to said parallel hollow wall molding compartments receiving said solidifying mixture such that said concrete wall panels are structurally reinforced by said steel rebar.
12. The panel forming apparatus of claim 10, wherein said solidifying mixture is vibrated by a series of vibrators prior to curing or hardening to remove trapped air bubbles from within said mixture of cement and other materials.
13. The panel forming apparatus of claim 3, wherein a worker or operator may access the top of each parallel hollow wall molding compartment to perform operations within said parallel hollow wall molding compartment while said solidifying mixture is received into said parallel hollow wall molding compartment.
14. The panel forming apparatus of claim 3, wherein said at least one wall forming panel is movably supported by steel V-groove wheels, wherein a first steel V-groove wheel is coupled with a proximal side of said at least one wall forming panel and operable with said first longitudinal side and a second steel V-groove wheel is coupled with a distal side of said at least one wall forming panel and operable with said second longitudinal side.
15. The panel forming apparatus of claim 3, wherein a texture/pattern liner is attached on opposing wall forming panels so that a texture and/or pattern is formed on the finished concrete wall panel.
16. The panel forming apparatus of claim 15, wherein a cap is placed on the top of said wall forming panel to prevent concrete from leaking between the panel and texture/panel liner.
17. The panel forming apparatus of claim 3, wherein said wall panel is provided with a texture or pattern on at least one face of said wall panel by securing a liner to at least one of said at least one wall forming panels.
18. The panel forming apparatus of claim 3, wherein said superstructure is shaped and configured to be capable of being attached to a movable platform for transporting said superstructure from a first location to a second location and forming said wall panels on said movable platform.
19. The panel forming apparatus of claim 18, wherein said movable platform is a truck trailer.
20. The panel forming apparatus of claim 18, wherein said trailer includes stabilizers for lifting the trailer wheels off of the ground before the solidifying mixture is supplied to said hollow molding compartment.
21. A method of manufacturing a plurality of wall panels, comprising:
- positioning at least one wall forming panel to a desired position within a superstructure having a rectangular profile including a first longitudinal side, a second longitudinal side, a proximal end side, and a distal end side, such that said at least one wall forming panel forms a plurality of hollow wall molding compartments, said hollow wall molding compartments capable of receiving a solidifying mixture that hardens or cures to form said wall panels;
- introducing said solidifying mixture into said hollow wall molding compartments;
- allowing said solidifying mixture to cure or harden to form said wall panels; and
- removing said wall panels from said superstructure after said solidifying mixture has sufficiently cured or hardened.
22. The method of manufacturing of claim 21, further comprising the steps of:
- positioning said at least one wall forming panel in a first position, said first position accommodating a worker in applying a release agent to at least one of said at least one wall forming panel, said proximal end side, and said distal end side; positioning said at least one wall forming panel in a second position, said second position being said desired position within said superstructure to form said plurality of hollow wall molding compartments; and
- positioning said at least one wall forming panel in a third position, said third position aiding in the removal or extraction of said wall panel from said hollow wall molding compartment.
23. The method of manufacturing of claim 21, wherein said solidifying mixture is comprised of cement and other materials such that said solidifying mixture hardens or cures to form concrete wall panels.
24. The method of manufacturing of claim 22, further comprising the step of positioning steel rebar within said hollow wall molding compartments prior to introducing said solidifying mixture into said hollow wall molding compartment such that said concrete wall panels are structurally reinforced.
25. The method of manufacturing of claim 21, further comprising the step of positioning a rectangular block of low density material within at least one of said plurality of hollow wall molding compartments such that the longitudinal length of said wall panel formed in said at least one of said plurality of hollow wall molding compartments is less than the longitudinal length of a similar wall panel formed in said at least one of said plurality of hollow wall molding compartments when said rectangular block of low density material is absent.
26. The method of manufacturing of claim 21, further comprising the step of positioning a spacer between one of said proximal end side or said distal end side and said at least one wall forming panel to vary the gap between said at least one wall forming panel and said proximal or distal end side; or positioning said spacer between said at least one wall forming panel and another of said at least one wall forming panel to vary the gap between said at least one wall forming panel and said other at least one wall forming panel.
27. The method of manufacturing of claim 21, further comprising the step of inserting a rubber sealing mat at the bottom of each of said plurality of hollow wall molding compartments such that each of said plurality of hollow wall molding compartments is sealed with respect to another of said plurality of hollow wall molding compartments to prevent said solidifying material from leaking between said plurality of hollow wall molding compartments.
28. The method of manufacturing of claim 21, further comprising the step of attaching a textured or patterned liner to at least one of said proximal end side, said distal end side, and said at least one wall forming panel to form a textured or patterned face on the respective wall panel associated with that said proximal end side, said distal end side, and said at least one wall forming panel.
29. The method of manufacturing of claim 21, further comprising the step of placing said superstructure under stress to maintain the integrity of the walls of said first and second longitudinal sides by coupling a tension system to said superstructure, said tension system acting as a counter force to a force exerted by said solidifying mixture on said walls of said first and second longitudinal sides after said solidifying mixture is introduced into said plurality of hollow wall molding compartments.
30. The method of manufacturing of claim 29, wherein said tension system comprises a tension wire cable capable of receiving a tensile force, and a tension cabling system, wherein said tension cabling system transfers said tensile force of said tension wire cable perpendicularly to said walls of said first and second longitudinal sides of said superstructure to maintain the integrity of said walls, and wherein said tension system further comprises: adjustable struts held perpendicular to said walls of said first and second longitudinal sides; a slotted receptacle for receiving said tension wire cable; and a screw apparatus, said screw apparatus functioning to adjust said tensile force of said tension wire cable by longitudinally lengthening or shortening said tension cabling system, wherein the lengthening or shortening of said tension cabling system functions to respectively stretch or relax said tension wire cable thereby adjusting said tensile force.
31. The method of manufacturing of claim 21, wherein the step of removing said wall panels is performed by placing a steel cap on the top of said solidifying mixture before it solidifies, said steel cap attachable to hooks for connecting said wall panel to a removal mechanism, said steel cap becoming imbedded within said wall panel after said solidifying mixture cures or hardens.
32. The method of manufacturing of claim 21, further comprising the step of lowering a series of vibrators into said plurality of hollow wall molding compartments after said solidifying mixture has been introduced into said plurality of hollow wall molding components, said series of vibrators acting to aid in the removal of air bubbles from within said solidifying mixture by vibrating said solidifying mixture within said plurality of hollow wall molding compartments.
33. The method of manufacturing of claim 21, further comprising the step of placing said superstructure onto the bed of a trailer and securing said superstructure with respect to said trailer for the purpose of transporting said superstructure from a first location to a second location and manufacturing said wall panels on said trailer.
Type: Application
Filed: Jun 12, 2008
Publication Date: Jan 1, 2009
Inventors: Lance Waite (Queen Creek, AZ), Terry Benton (Mesa, AZ), Mark Williamson (Sandy, UT)
Application Number: 12/138,237
International Classification: E04D 15/00 (20060101);