PREFABRICATED STRUCTURE FOR USE IN CONSTRUCTING OUTDOOR FIREPLACES AND THE LIKE AND METHOD OF MAKING SAME
A method for off-site manufacture of prefabricated monolithic fireplaces etc comprising a plurality of concrete blocks ; the method comprising the steps of constructing a first layer of blocks, providing a steel frame and securing the same to the blocks and to a second layer of blocks constructed atop the first layer, and constructing additional layers of blocks sequentially atop the second layer each block being adhesively secured to each of its adjacent blocks.
Outdoor fireplaces, grill units, bars and even complete outdoor kitchens have been constructed on-site from concrete blocks and the like for some time and have been generally satisfactory. The cost of on-site construction, however, is substantial and quality control may be difficult to monitor and maintain in on-site construction resulting in a lack of structural integrity of the units and even in structural failure over time.
It is the general object of the present invention to provide a prefabricated monolithic structure of high structural integrity for use in the efficient construction of outdoor fireplaces and the like, and an off-site method of making the same.
It is a further object of the invention to provide a structure of the type mentioned which includes an integral high strength metallic frame resulting in a high degree of structural integrity of the overall structure, and which in turn facilitates the efficient transportation and on-site installation of the structure.
A still further object of the invention resides in the provision of lifting devices particularly well adapted to lift, transport and install the aforesaid structure.
SUMMARY OF THE INVENTIONIn fulfillment of the aforesaid objects and in accordance with the present invention, an off-site prefabricated structure of concrete blocks or the like is provided with a first or base layer or course of blocks outlining the perimeter configuration of the structure. A rust proof frame of high strength metallic construction is provided with a configuration substantially the same as the base layer of blocks and is fixedly secured to the base layer of blocks in supporting relationship therewith to maintain their relative positions with respect to each other. A plurality of additional layers or courses of blocks are then provided atop the base layer of blocks and each block is affixed to each of its adjacent blocks by an adhesive bonding material.
In a presently preferred form, the blocks of the first layer are somewhat wider than those of the second layer to provide a narrow substantially horizontal inwardly extending shelf defined by the top surfaces of the first layer of blocks inwardly around the perimeter of the structure. The structural frame is generally L shaped in cross sectional configuration with one leg arranged horizontally and engaging and affixed to the top surface of the base layer of blocks and with an integral vertical leg engaging and affixed to the inner surfaces of the second layer of blocks. Preferably, the structural frame is both bolted to and secured adhesively to substantially all of the blocks in both the first and second layers of blocks.
While other high strength materials may be employed, the metallic frame is preferably constructed of structural strength steel with a rust proof coating. Various adhesives may also be used with a high strength masonry water-based bonding agent presently preferred.
In the preferred practice of the method of the present invention, conventional off-site facilities conducive to efficient quality control and efficient low cost production are provided. A first layer of blocks is provided in a desired perimeter configuration and adhesively affixed followed by a second narrow layer of blocks, which defines the shelf for receiving the frame. The frame is then affixed in secure engagement with both the first and second layers of blocks both adhesively and with suitable bolts.
Additional layers of blocks are then provided atop the second layer of blocks with each block in each layer throughout adhesively secured to each of its adjacent blocks.
On completion of one or more structures required for a particular outdoor unit, the structures are transported for on-site installation on large trucks and lifting devices of the present invention, to be described hereinbelow, may be employed for loading and unloading the trucks and for locating the structures in their desired on-site positions. A fireplace, for example may require two structures one atop the other. Other units may require two or more structures assembled in various side-by-side arrangements etc.
Referring particularly to
In
In
The frame 56 is of a high-strength rust-proof metallic construction such as structural steel and preferably takes an L shape configuration in cross-section as best illustrated in
In accordance with the method of the invention, a plurality of blocks 78, 78 arranged in vertically stacked relationship may be assembled in a desired number of layers or courses atop the second layer of blocks 74, 74 with each block adhesively secured to all adjacent blocks to provide a monolithic structure of high structural integrity.
A first method of transport for the prefabricated structures involves the aforesaid openings 62, 62 and brackets 76, 76 and a conventional fork lift truck. As will be seen in
Secondly, and when the first method of transport is impractical or impossible to achieve, transport may be accomplished as illustrated in
Finally, it should be noted that the second method of transport has the advantage of ease in effecting a slight horizontal adjustment during final positioning of a structural unit. When the depending unit is held slightly above its final position by a fork lift, manual force can be applied laterally by attending workmen in a slight swinging movement for horizontally positioning within a matter of inches.
From the foregoing it will be apparent that a method has been provided for prefabricating a concrete block unit of high structural integrity at economic advantage. Highly effective methods of transport have also been provided.
Claims
1. A method for the off-site manufacture of prefabricated monolithic structures comprising a plurality of blocks formed of concrete or the like and used in constructing outdoor fireplaces, grill and countertop units, bars and the like; the method comprising the steps of constructing a base layer of blocks in a desired configuration representing the perimeter of a structure, providing a rust proof structural frame of high strength metallic construction having a configuration substantially the same as that of the base layer of blocks, fixedly securing the frame in supporting relationship with interior surfaces of the base layer of blocks, sequentially constructing additional layers of blocks atop the first layer of blocks and atop each other, and affixing each of the blocks in each of the additional layers of blocks to each of its adjacent blocks by means of a high strength adhesive bonding material.
2. A method as set forth in claim 1 wherein the structural frame is also fixedly secured in supporting relationship with interior surfaces of the blocks in a second layer of blocks.
3. A method as set forth in claim 2 wherein the blocks of the first layer are somewhat wider than those of the second layer to provide a narrow substantially horizontal inwardly extending shelf defined by the top surfaces of the first layer of blocks around the perimeter of the structure, and wherein the structural frame is generally L shaped in cross sectional configuration with one leg arranged horizontally and engaging and affixed to the top surfaces of the base layer of blocks and with an integral vertical leg engaging and affixed to adjacent vertical interior surfaces of the second layer of blocks.
4. A method as set forth in claim 3 wherein the structural frame is both bolted to and secured adhesively to substantially all of the blocks in both the first and second layers of blocks.
5. A method as set forth in claim 1 wherein a high strength masonry adhesive is employed in bonding the blocks to each other.
6. A method as set forth in claim 1 wherein an opening of substantial size is provided in a front sidewall of the structure so as to enable use of the same as a fireplace.
7. A method as set forth in claim 6 wherein a second structure similar to the first and having a vertical through opening is fabricated and is placed atop the first structure to serve as a chimney.
8. A method as set forth in claim 6 wherein a horizontal rust proof metallic header is provided and installed across the top of the fireplace opening with opposite end portions secured between vertically adjacent layers of blocks.
9. A method as set forth in claim 1 wherein a substantially horizontal cooking grill of rust proof metallic construction is provided and mounted in a structure.
10. A method as set forth in claim 9 wherein a second structure similar to the first is prefabricated and positioned adjacent and in close proximity to the first structure, and wherein a large unitary countertop is provided and positioned atop both the first and second structures, an opening being provided in the countertop member to receive the grill.
11. A method as set forth in claim 1 wherein a second structure similar to the first is prefabricated and positioned adjacent and in close proximity to the first, wherein a large unitary countertop is provided and positioned atop both the first and second structures, and wherein a sink is provided in one portion of the countertop.
Type: Application
Filed: Dec 15, 2014
Publication Date: Jun 16, 2016
Inventor: Raymond Paulding (Palm City, FL)
Application Number: 14/569,852