PRE-CAST CONCRETE STRUCTURES

Abstract

A system is taught comprising a first plain end concrete structure comprising two side faces extending horizontally to end in two end faces and a second fork end concrete structure comprising two side faces extending horizontally to end in two fork ends; said fork ends each comprising a pair of fork walls that define a slot. The system further comprises a base and a rigid support member embedded in the base, and received within said slot. The width of the slot of one or more of the fork ends at the mouth is sized to receive the end face of the plain end structure and the width of the slot increases from the mouth to the fork end face, and wherein the rigid support member is locked into the slot by the aggregate filler material. A system of stacked structures is taught, said system comprising one or more stacking structures, each comprising two side faces extending vertically to end in a bottom face and a top face, said top face comprising a top profile and said bottom face comprising a bottom profile. The one or more stacking structures are vertically stackable onto each other such that the top profile of a lower structure interfits with the bottom profile of a higher structure in the vertical stack.

Description

FIELD OF THE INVENTION

The present invention relates to pre-cast concrete structures, systems of pre-cast concrete structures and methods of assembling pre-cast concrete structures.

BACKGROUND

Pre-cast concrete structures are commonly used in construction applications. They are often preferred over cast-in-situ concrete structures since casting conditions can be regulated at an off-site casting facility. The pre-cast structure can then be shipped and assembled at the site with less labour and less stringent quality requirements. It is also possible to add a number of design features to pre-cast concrete structures such as decorative texturing and structural features.

Pre-cast concrete structures such as fences, walls, sound barriers, retaining walls are typically cast as full height structures that are then erected on site by means of heavy lifting equipment such as cranes. Due to the need for specialized equipment, the delivery, storage and erection of concrete fences and barriers must be timed precisely to coincide with availability of the heavy lifting equipment on site.

Pre-cast concrete structures are often cast according to specific construction requirements for height, length and width. This requires exact knowledge of the construction requirements prior to casting and shipping. Should construction conditions change and taller or shorter structures be required, there is no recourse but to re-cast new structures to the amended specifications.

A need and interest therefore exists in the art to develop improved pre-cast concrete structures and methods of assembling pre-cast concrete structure systems such as walls, sound barriers, fences and retaining walls.

SUMMARY

A system is taught comprising a first plain end concrete structure comprising two side faces extending vertically to end in a bottom face and in a top face and extending horizontally to end in two end faces, and a second fork end concrete structure comprising two side faces extending vertically to end in a bottom face and in a top face and extending horizontally to end in two fork ends; said fork ends each comprising a pair of fork walls extending from a fork end face to a mouth to define a slot. The system further comprises a base for receiving thereupon the first plain end concrete structure and the second fork end concrete structure, a rigid support member embedded in the base, and received within said slot adjacent the fork end face and an aggregate filler material for filling voids between the support member and the slot. A width of the slot of one or more of the fork ends at the mouth is sized to receive the end face of the plain end structure and the width of the slot increases from the mouth to the fork end face and the rigid support member is locked into the slot by the aggregate filler material.

A further system of stacked structures is taught, said system comprising: one or more stacking structures, each comprising two side faces extending vertically to end in a bottom face and a top face, said top face comprising a top profile and said bottom face comprising a bottom profile wherein said one or more stacking structures are vertically stackable onto each other such that the top profile of a lower structure interfits with the bottom profile of a higher structure in the vertical stack. The stacking structures comprise one or more plain end concrete structures wherein the two side faces extend horizontally to end in two plain ends; one or more fork end concrete structure wherein the two side faces extend horizontally to end in two fork ends; said fork ends each comprising a pair of fork walls that define a slot; a base for receiving thereupon a lower fork end concrete structure and a lower plain end concrete structure; a rigid support member embedded in the base and extending to a height equal to the height of the stacked system, said rigid support received within said slot, and an aggregate filler material for filling voids between the support member and the slot. The slot has a width sized to receive an end face of one or more first plain end structures such that the end face of the plain end structure is disposed adjacent the rigid support member and the rigid support member is locked into the slot by the aggregate filler material.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in greater detail, with reference to the following drawings, in which:

FIG. 1 is perspective view of one embodiment of the present pre-cast concrete structures;

FIG. 2 is a to plan view of one example of the present pre-cast concrete structures;

FIG. 3 is a top plan view of another example of the present pre-cast concrete structures;

FIG. 4 is a side elevation view of one embodiment of the pilings and support members of the present invention;

FIG. 5 is a top plan view of one embodiment of a system of the present invention;

FIG. 6 is a top plan view of another embodiment of a system of the present invention;

FIG. 7 is a top plan view of another embodiment of a system of the present invention;

FIG. 8 is a perspective view of one embodiment of the present pre-cast concrete system; and

FIG. 9 is a side elevation view of another embodiment of the present pre-cast concrete system.

DESCRIPTION OF THE INVENTION

The present invention relates to pre-cast concrete structures and systems of pre-cast concrete structures. More specifically, the present invention relates to pre-cast concrete structures for use as walls, fences, sound barriers, retaining walls, dividers or other well known constructional and structural elements. The structures of present invention can be easily and economically formed, transported, erected and stacked as needed. The present structures further do not require heavy lifting equipment such as cranes for set up or assembly.

The structures of the present invention can be made from a number of well-known materials including reinforced concrete or any construction materials composed of aggregates and cementitous materials. Other fluid or semi-fluid materials that can be hardened or solidified may also be used, as well as filler materials joined together with a bonding agent or resin.

An example of the system of structures of the present invention is shown in FIG. 1. The system comprises a pre-cast plain-end structure 2 and a pre-cast forked-end structure 4. With reference to FIG. 2, the plan end structure 2 comprises two preferably substantially parallel side faces 6a, 6b (collectively referred to as side faces 6) that extend horizontally to end in end faces 8a, 8b (collectively referred to as end faces 8), and extend vertically to end in a bottom face 10 and a top face 12.

The side faces 6 may preferably comprise a texture or decorative pattern such as, for example plain, textured concrete, revealed concrete, stone, rock, masonry block or brick. Such texture or pattern is more preferably bounded horizontally by a plain surface directly adjacent end faces 8. Further preferably, the texture or pattern may also be bounded vertically by a plain surface directly adjacent top face 12 and bottom face 10.

The fork-end structure 4 is depicted in FIG. 3, and comprises a pair of preferably substantially parallel side faces 14a, 14b (collectively referred to as side faces 14) that extend vertically to end at a bottom face 16 and a top face 18. The side faces 14 also extend horizontally to end at two fork ends 20 and 22. The side faces 14 may preferably comprise a texture or decorative pattern such as, for example plain, textured concrete, revealed concrete, stone, rock, masonry block or brick. Such texture or pattern is more preferably bounded horizontally by a plain surface directly adjacent fork ends 20, 22. Even further preferably the texture or pattern may also be bounded vertically by a plain surface directly adjacent bottom face 16 and top face 18.

Fork ends 20, 22 comprise a pair of fork walls 24 that extend from the bottom face 16 to the top face 18. The fork walls 24 are connected at a first end to define a fork end face 26 and are open to a mouth 28 at a second end to thereby define a slot 30. In one embodiment, the fork walls 24 are preferably substantially parallel to one another. A width of the slot 30, as defined by a distance between fork walls 24, is preferably equal to or greater than a width of the end face 8, to receive end face 8 and support plain end structure 2 in an upright position.

In such a manner, plain end structures 2 and fork end structures 4 can be inter-fit to form a system such as a wall, fence, sound barrier, divider or retaining wall.

Side faces 6a, 6b and 14a, 14b are shown as being preferably substantially planar and parallel to one another. However it is also possible for the side faces 6a, 6b and 14a, 14b to define a curved surface, to comprise ridges or projections, or to be wholly or partially non-parallel, to thereby define varying thicknesses between the side faces. These and other variations in side faces 6a, 6b and 14a, 14b can be envisioned and are encompassed by the scope of the present invention.

In a preferred embodiment, one or both of the plain end structure 2 and the fork end structure 4 may be cast with a reinforcement 38 embedded within the structure for added strength and durability. Such reinforcement 38 may take the form of a steel plate, rebar, steel mesh and any other well known reinforcing products in the art.

In one method of assembly of a system of the present invention, a base 34, preferably in the form of a cast-in-situ pile, is poured and a rigid support member 36 is embedded into the base 34. This is depicted in FIG. 4. The base can be cast by any well known means in the art and may include reinforcing material 46 such as rebar, metal mesh, a wire cage and other well known reinforcement.

Alternatively, the support member 36 may preferably be reinforced with rebar 46 and placed in a pile hole and then the base 34 may be poured around the reinforced support member 36. In this embodiment, rebar 46 is most preferably welded to the support member 36 prior to insertion in the pile hole. Many other means of pouring the base 34, reinforcing the base 34 or embedding a support member 36 in a base 34 would be known and well understood by a person of skill in the art and are encompassed by the scope of the present invention.

Said support member 36 can preferably be any elongated rigid member including, but not limited to posts, rods, tubes, ‘I’ beams and ‘H’ beams. The support member is typically made of steel and is most preferably a wide flange beam such as a steel ‘H’ beam. Such support members 36 preferably extend above the base 34 to a final height of the assembled system.

Once cured, a fork end structure 4 can be supported on the pile 34, with the support member 36 being accommodated in an inner portion of the slot 30 near the fork end face 26, as depicted in the right hand side of FIG. 5. The end faces 8 of a plain end structure 2 can then be received in the slot 30 adjacent support member 36.

In an alternate embodiment, the support beam preferably comprises one or more flanges on one or more sides, such as, for example a wide flange ‘H’ beam support member 36. In such cases it is also possible for one or more of end faces 8 of a plain end structure 2 to be formed with a projection 42 that can be received into said one or more flanges of the support member. One example of this configuration is shown in FIG. 6. In a further alternative embodiment, the fork end face 26 may comprise a further projection 44 to be received into another flange of the support member 36. It would be understood by a person of skill in the art that one, both or none of projections 42 and 44 could be present on the present system without departing from the scope of the present invention and that the support beam may comprise one or more flanges on one or both of its sides.

Preferably, any void space between the support member 36 and the slot 30 is filled with aggregate filler 48. The aggregate filler 48 provides additional rigidity and support to the system and helps to lock the structures of the system in place. More preferably, the aggregate filler is washed rock. Most preferably the void is filled with ¾ inch (2 cm) washed rock aggregate filler.

Aggregates are well known in the art to be a mixture of rocks, gravel and more preferably pebbles of differing sizes. The aggregate filler 48 serves to provide additional rigidity and support to the system and to lock the support members 36 and structures in place. The aggregate filler 48 is preferably not a liquid, like liquid concrete, which can leak out of the slot and may require time to set. The aggregate filler 48 rather provides rigidity and locking support as soon as it is filled into the voids. Aggregate fillers 48 are further advantageous in that there is also no concern with cold temperature applications, since drying, curing or setting is not required for aggregate filler.

As the rocks of the aggregate filler 48 settle against one another and against the surfaces of the support member 36 and structures, friction causes the aggregate filler 48 to lock against any abutting surface, thereby providing a frictional locking of the support member 36 into place.

Since aggregate filler 48 of the present invention provides a frictional lock, and not a cement bond, between structures and the rigid support member 36, the components of the present system can be removed or replaced as needed for maintenance and repair, without breaking of or damage to adjoining structures or to the support member 36.

The need for repair of these types of systems is not uncommon occurrence. As such, the ability to remove and replace separate structures of the system without damaging the entire system is an important need.

Furthermore, the plain end structures 2 of the present invention provide the advantage that their simple design allows for ease of removal without the concern of protruding fork segments breaking off or of damage to the support member. Once the plain end structure 2 is removed, the frictional lock of the aggregate filler 48 is released and the forked end structure 4 can then be removed with ease.

A preferred profile of fork walls 24 are shown in FIGS. 5 and 7, in which the width of the slot 30 increases from the mouth 28 to the fork end face 26 such that the width of the slot at the mouth 28 is still sized to receive and support an end face 8. The increased slot width beyond the mouth 28 can be provided by any known shape or profile of the fork walls 24. For example, as depicted in FIG. 7, the fork walls 24 may angle inwardly from the mouth 28 to the fork end face 26. Alternatively, as depicted in FIG. 5, the fork walls 24 may be substantially parallel to one another at the fork end face 26 and then angle inwardly to form a pair of projections 32 at the mouth 28, said projections defining a width sufficient to receive and support an end face 8 of a plain end structure 2. Other fork wall 24 profiles are also possible, including a curved fork wall 24 profile, and it would be understood by a person of skill in the art that such profiles are also encompassed by the scope of the present invention.

The increased width of the slot 30 depicted in alternative fork end 22, may be present on both fork ends of a fork end structure 4, or may be present on only one end, or alternatively may not be present at all.

The increased width of the slot 30 resulting from fork end 22, may advantageously accommodate a larger, and preferably therefore stronger, support members 36. The profile of the fork walls 24 of fork end 22 may also advantageously serve to better retain the aggregate filler 48 used to fill the void between the support member 36 and the slot 30.

In a further preferred embodiment, fork end structures 4 may be constructed without side walls 14, in the form of a column. In such an embodiment, the column form of fork end structure may comprises one or more slots 30 formed by one or more pairs of fork walls 24 for receiving one or more plain end structures 2 therein. The slots 30 may be formed in line with one another such that a linear fence or wall system may be formed with plane end structures 2 in spaces of small length. Alternatively, the slots 30 may be at perpendicular angles to one another such that plane end structures 2 are received therein to form a corner of a fence or wall system. Finally, a singular slot 30 may be formed in a column form of a fork end structure to form an end piece to a fence or wall system.

The structures 2, 4 of the present system may be formed in any dimensions of height, width and depth that are preferred for the formation of systems of sound barriers, fences, retaining walls and other related systems.

In a preferred embodiment, illustrated in FIG. 8, two or more plain end structures 2 and two or more fork end structures 4 may be stacked on top of each other to obtain the desired final system height. Preferably, to aid in stacking, a profile 40 is formed on each of the bottom face 10 and top face 12 of the plain end structure 2 and on the top face 18 and bottom face 16 of the fork end structure 4. These profiles 40 inter-fit when the structures are stacked to facilitate alignment of the structures 2, 4 upon one another, such that no strain is place on rigid support member 36, which extends through stacked slots 30. Profiles 40 also provide a connection between the stack structures 2, 4 with minimal voids for water or light ingress. In the case of systems of the present structures 2, 4 being used as sound barriers, the profiles 40 also serve to improve sound insulation.

The profiles 40 may be of any shape and configuration well known in the art and can include, for example, shiplap profiles, tongue-and-groove profiles, dovetail profiles, and any other profiles that interfit upon stacking, as depicted in FIG. 9. Since the structures 2, 4 of the present invention are pre-cast concrete, the profile 40 is more preferably of such shape that can be easily created from a mould or form and cast with minimum distortion or breaking. Most preferably the profile 40 comprises a ship-lap joint, is also depicted in FIG. 9.

The structures 2, 4 of the present system are most preferably cast in heights of 1 foot (30 cm), 2 feet (60 cm) or 3 feet (91 cm). At such heights, the structures 2,4 are advantageously easily maneuvered and lifted into place by smaller equipment such as bobcats, forklifts, telescopic handlers and the like, which are commonly found on construction sites. The preferred heights of the structures 2, 4 do not require the use of larger specialty equipment such as cranes for assembly of the present system.

The support member 36 of the present invention preferably extends above the base 34 to the full height of the present assembled system. Thus, for example in assembling a system comprising a stack of three structures, each being 3 feet (91 cm) in height, the support member 36 would extend 9-foot (2.75 m) above the base 34.

As the height of the assembled system increases, and correspondingly the height of the support member 36 above base 34, the depth that the support member 36 is embedded into the base 34 is also preferably increased. This arrangement advantageously improves support of the system against increased wind loads as the height of the system increases. The thickness of the support member and its cross sectional size is also preferably increased with increasing height of the stacked system and increased height of the support member. Some examples of ratios of system height, support member size and embedment depth of a wide flange or I- beam support member are given in Table 1 below:

TABLE 1
Support Member Size and Embedment
Depth as a Function of System Height
System Height	Base Depth	Support Member Size	Support Member
Range (mm)	(mm)	(mm)	Embedment (mm)
1500-2000	2440	19 mm thickness ×	600
		100 flange width
2000-2500	2440	19 mm thickness ×	800
		100 flange width
2500-3000	2440	19 mm thickness ×	800
		100 flange width
3000-3500	2440	24 mm thickness ×	1000
		130 mm flange width
3500-4000	2400	24 mm thickness ×	1000
		130 mm flange width

In a further preferred embodiment, the assembled system of the present invention may further comprise a coping (not shown) covering the top faces 12, 18 of structures 2, 4 respectively. A sealing means (not shown) may preferably cover fork ends 22, 24 to prevent ingress of water into voids between the support member 36 and plain ends 8, and the slot 30. Such sealing means can be any suitable means of sealing the fork ends 22, 24 including but not limited to caps, concrete covers, flashing, membranes or the use of sealants and the like.

In the foregoing specification, the invention has been described with a specific embodiment thereof; however, it will be evident that various modifications and changes may be made thereto without departing from the scope of the invention.

Claims

1. A system comprising: wherein a width of the slot of one or more of the fork ends at the mouth is sized to receive the end face of the plain end structure and the width of the slot increases from the mouth to the fork end face, and wherein the rigid support member is locked into the slot by the aggregate filler material.

a) a first plain end concrete structure comprising two side faces extending vertically to end in a bottom face and in a top face and extending horizontally to end in two end faces;

b) a second fork end concrete structure comprising two side faces extending vertically to end in a bottom face and in a top face and extending horizontally to end in two fork ends; said fork ends each comprising a pair of fork walls extending from a fork end face to a mouth to define a slot;

c) a base for receiving thereupon the first plain end concrete structure and the second fork end concrete structure;

d) a rigid support member embedded in the base, and received within said slot adjacent the fork end face; and

e) an aggregate filler material for filling voids between the support member and the slot,

2. The system of claim 1, wherein the fork walls of the slot comprise projections at the mouth, said projections defining a width sufficient to receive an end face of a plain end structure.

3. The system of claim 1, wherein the side faces of the first plain end structure and the second fork end structure comprise a texture or decorative pattern.

4. The system of claim 3, wherein the texture or decorative pattern is selected from the group consisting of plain, textured concrete, revealed concrete, stone, rock, masonry block and brick.

5. The system of claim 4, wherein the texture or pattern is bordered by a plain surface directly adjacent the top faces, bottom faces, the end faces and the fork ends.

6. The system of claim 1, wherein the base is a cast-in-situ pile.

7. The system of claim 6, wherein the cast-in-situ pile is reinforced with reinforcing material selected from the group consisting of rebar, metal mesh and wire cage.

8. The system of claim 6, wherein the support member is reinforced with reinforcing material and the pile is cast around the support member to embed said support member.

9. The system of claim 8, wherein the support member is welded with rebar for reinforcement.

10. The system of claim 1, wherein the plain end structure comprises reinforcement embedded within the structure.

11. The system of claim 10, wherein the fork end structure comprises reinforcement embedded within the structure.

12. The system of claim 21, wherein the reinforcement is selected from the group consisting of a steel plate, rebar and steel mesh.

13. The system of claim 1, wherein the support member is selected from the group consisting of posts, rods, tubes, ‘I’ beams and ‘H’ beams.

14. The system of claim 13, wherein the support member is a wide flange steel ‘H’ beam.

15. The system of claim 1, wherein the support member extends above the base to a height equal to a height of the system.

16. The system of claim 15, wherein the first plain end structures and the second fork end structures have a height from bottom face to top face that is selected from the group consisting of 1 foot (30 cm), 2 feet (60 cm) and 3 feet (91 cm).

17. The system of claim 1, wherein the first plain end structures and the second fork end structures are assembled by use of equipment selected from the group consisting of bobcats, forklifts and telescopic handlers.

18. The system of claim 1, wherein: wherein the first projection is received adjacent to said one or more flanges of the rigid support member.

a) one or more of said end faces of said first plain end concrete structure comprise a first projection; and

b) one or more sides of said rigid support member comprises one or more flanges,

19. The system of claim 1, wherein: wherein the second projection is received adjacent to said one or more flanges of the rigid support member.

a) one or more of said fork end faces of said second fork end concrete structure comprise a second projection; and

b) one or more sides of said rigid support member comprises one or more flanges,

20. The system of claim 1, wherein: wherein the first projection and the second are received adjacent to said one or more flanges of the rigid support member.

a) one or more of said end faces of said first plain end concrete structure comprise a first projection;

b) one or more of said fork end faces of said second fork end concrete structure comprise a second projection; and

c) one or more sides of said rigid support member comprises one or more flanges,

21. A system of stacked structures, said system comprising: one or more stacking structures, each comprising two side faces extending vertically to end in a bottom face and a top face, said top face comprising a top profile and said bottom face comprising a bottom profile wherein said one or more stacking structures are vertically stackable onto each other such that the top profile of a lower structure interfits with the bottom profile of a higher structure in the vertical stack; wherein the stacking structures comprise; wherein said slot has a width sized to receive an end face of one or more first plain end structures such that the end face of the plain end structure is disposed adjacent the rigid support member and wherein the rigid support member is locked into the slot by the aggregate filler material.

a) one or more plain end concrete structures wherein the two side faces extend horizontally to end in two plain ends;

b) one or more fork end concrete structure wherein the two side faces extend horizontally to end in two fork ends; said fork ends each comprising a pair of fork walls that define a slot;

c) a base for receiving thereupon a lower fork end concrete structure and a lower plain end concrete structure;

f) a rigid support member embedded in the base and extending to a height equal to the height of the stacked system, said rigid support received within said slot, and

g) an aggregate filler material for filling voids between the support member and the slot,

22. The system of claim 21, wherein the top profile and bottom profile are selected from the group consisting of shiplap profiles, tongue-and-groove profiles and dovetail profiles.

23. The system of claim 22, wherein the profile is a ship-lap profile.

24. The system of claim 21, wherein embedment of the support member into the base increases with increasing height of the stacked system.

25. The system of claim 21, wherein the thickness and cross sectional size of the support member increases with increasing height of the stacked system.