HARDENABLE MATERIAL STRUCTURE CONSTRUCTION APPARATUS AND METHOD

Abstract

A construction apparatus constituted of: a support structure comprising a support frame, a first inner support arm extending from the support frame and a first outer support arm extending from the support frame; a support extension member; a first enclosure member; and a second enclosure member, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined therebetween, wherein the first outer support arm is juxtaposed with the outer face of the first enclosure member, wherein the first inner support arm is juxtaposed with the outer face of the second enclosure member, wherein the support extension member extends through the first enclosure member and the second enclosure member, and wherein the first end of the support extension member is secured to the first outer support arm and the second end of the support extension member is secured to the first inner support arm.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from: U.S. patent application Ser. No. 14/682,133, filed Apr. 9, 2015 and titled “HARDENABLE MATERIAL STRUCTURE CONSTRUCTION APPARATUS AND METHOD”; Israeli patent application S/N 239991, filed Jul. 16, 2015 and titled “WALL CONSTRUCTION SYSTEM AND METHOD”; and U.S. provisional patent application Ser. 62/259,693, filed Nov. 25, 2015 and titled “HARDENABLE MATERIAL STRUCTURE CONSTRUCTION APPARATUS AND METHOD”. The entire contents of each of the above are incorporated herein by reference.

TECHNICAL FIELD

The invention relates generally to the field of construction and in particular to a hardenable material structure construction apparatus and method.

BACKGROUND

Concrete has been used for construction since ancient times and in recent years several different types of hardenable material, i.e. liquid material which harden into a solid material, which provide similar or superior properties to concrete, have been developed. Traditionally, in order to construct a concrete wall a metal grid is erected and a form is built for the concrete with a large number of wooden beams on both sides, the wooden beams connected to each other and otherwise reinforced so as not to buckle when the concrete is poured. Concrete is then poured between the erected wooden beams and left to harden. After the concrete hardens, the wooden beams are removed thereby exposing the concrete wall. The inside of the concrete wall is then typically insulated with thermal insulation material and a cinder block wall is erected over the thermal insulation. Additionally, a facade is built on the outer side of the concrete wall, generally secured to the concrete wall with plaster.

Unfortunately, the traditional method of concrete construction suffers from several disadvantages. Firstly, erecting the many wooden beams to produce a form for the concrete requires significant manual labor, which increases cost and complexity. Secondly, providing thermal insulation within the building creates thermal bridges at the ceiling/floor of each level. Although methods for thermally insulating the outer side of the concrete wall do exist, outdoor thermal insulation adds costs and complexity due to the unique challenges of outdoor construction. Additionally, the plaster securing the insulation to the outside of the concrete wall is porous and any water droplets which enter the plaster will expand when heated during the day, thereby causing an expansion of the plaster. Such an expansion will apply pressure to the facade, which can cause damage thereto. In the event that the facade is made of stone, the stones can fall off the building, which can cause damage and bodily harm. The same disadvantage applies for a facade directly secured to the concrete wall with plaster. A third disadvantage is that a stone facade secured with plaster is only weakly secured to the concrete wall, thereby risking that the stones can fall off.

Although many premade concrete forms have been developed to reduce the amount of wooden beam construction on site, the other disadvantages still remain. Additionally, although wooden beam construction is reduced, each concrete form type presents new challenges which increase cost and complexity.

It is therefore an object of the present disclosure to overcome at least part of the disadvantages of the prior art.

SUMMARY OF THE INVENTION

Accordingly, it is a principal object of the present invention to overcome disadvantages of prior art methods and arrangements of hardenable material construction. This is provided in one embodiment by a temporary hardenable material construction apparatus comprising: a support structure comprising a support frame, a first inner support arm extending from the support frame and a first outer support arm extending from the support frame; at least one support extension member, the at least one support extension member exhibiting a first end and a second end opposing the first end; a first enclosure member exhibiting an inner face and an outer face opposing the inner face; and a second enclosure member exhibiting an inner face and an outer face opposing the inner face, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined between the inner face of the first enclosure member and the inner face of the second enclosure member, wherein the first outer support arm is juxtaposed with the outer face of the first enclosure member, wherein the first inner support arm is juxtaposed with the outer face of the second enclosure member, wherein the at least one support extension member extends through the first enclosure member and the second enclosure member such that the first end of the at least one support extension member extends past the outer face of the first enclosure member and the second end of the at least one support extension member extends past the outer face of the second enclosure member, and wherein the first end of the at least one support extension member is secured to the first outer support arm and the second end of the at least one support extension member is secured to the first inner support arm.

In one embodiment, the support structure further comprises a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the first outer support arm being secured to the first extension arm and the extension of the first inner support arm from the support frame responsive to the first inner support arm being secured to the first extension arm. In one further embodiment, the support structure further comprises a second extension arm extending from the support frame, a second inner support arm secured to the second extension arm and a second outer support arm secured to the second extension arm, wherein the at least one support extension member comprises a plurality of support extension members, the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of the plurality of support extension members secured to the second inner support arm.

In one embodiment, the support structure further comprises a plurality of elongated strengthening arms, each exhibiting a first end and a second end opposing the first end, wherein the first end of each of the plurality of elongated strengthening arms is secured to the first inner support arm and the second end of each of the plurality of elongated strengthening arms is secured to the second inner support arm. In another embodiment, the distance between the support frame and the second enclosure member is 60-120 centimeters.

In one embodiment, the distance between the support frame and the second enclosure member is 80-100 centimeters. In another embodiment, the apparatus further comprises a plurality of free extension members, each of the plurality of free extension members exhibiting a first end and a second end opposing the first end, wherein each of the plurality of free extension members extends through the first enclosure member and the second enclosure member, and wherein the first end of each of the plurality of free extension members is not secured to the first outer support arm and the second end of each of the plurality of free extension members is not secured to the first inner support arm.

In one embodiment, the first inner support arm extends across the entirety of the outer face of the second enclosure member, wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member. In another embodiment, the first enclosure member comprises: a plurality of strips; and a plurality of slabs, each of the plurality of slabs exhibiting a first face, a second face opposing the first face, a first side extending from the first face to the second face and a second side opposing the first side, each of the first side and the second side exhibiting a slit therealong, the slit configured to receive a respective one of the plurality of strips, wherein the first side of each of the plurality of slabs faces the second side of another of the plurality of slabs, a respective one of the plurality of strips disposed within the slit of the first side of the respective slab and within the slit of the second side of the another respective slab, and wherein each of the at least one support extension member extends through a respective one of the plurality of strips. In one further embodiment, the apparatus further comprises a plurality of L-shaped corner members, each of the L-shaped corner members exhibiting a first end and a second end perpendicular to the first end, the slit of each of the plurality of slabs further configured to receive one of a first end and a second end of a respective one of the plurality of L-shaped corner members, wherein the at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, the first end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a first of the pair of first enclosure members and the second end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a second of the pair of first enclosure members.

In one embodiment, the first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members, wherein each of the at least one support extension member extends through a respective one of the plurality of facade securing elements. In another embodiment, the first enclosure member comprises: an outer layer exhibiting an inner face and an outer face opposing the inner face, the outer face of the first enclosure member comprising the outer face of the outer layer; and an insulation layer exhibiting an inner face and an outer face opposing the inner face, the inner face of the insulation layer facing the inner face of the second enclosure member, the outer face of the insulation layer facing the inner face of the outer layer.

In one further embodiment, the outer face of the insulation layer is in direct contact with the inner face of the outer layer. In one yet further embodiment, the apparatus further comprises: a grid assembly disposed within the defined space; at least one securing member, each of the at least one securing members disposed on a respective one of the at least one support extension member and juxtaposed with the insulation layer to secure the insulation layer to the outer layer; and wherein the grid assembly is secured to the at least one extension member so as to separate the grid assembly from the insulation layer by at least a predetermined distance.

In one independent embodiment, a structure is provided, the structure comprising: a plurality of extension members, each of the plurality of extension members exhibiting a first end and a second end opposing the first end; a first enclosure member exhibiting an inner face and an outer face opposing the inner face; and a second enclosure member exhibiting an inner face and an outer face opposing the inner face, the second enclosure member positioned in parallel with the first enclosure member such that a space is defined between the inner face of the first enclosure member and the inner face of the second enclosure member, the space filled with a wall layer of hardenable material; wherein each of the plurality of extension members extends through the first enclosure member and the second enclosure member, and wherein the first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members, wherein each of the plurality of extension members extends through a respective one of the plurality of facade securing elements.

In one embodiment, each of the plurality of facade securing elements comprises a strip, wherein each of the plurality of facade members comprises a slab, each of the plurality of slabs exhibiting a first face, a second face opposing the first face, a first side extending from the first face to the second face and a second side opposing the first side, each of the first side and the second side exhibiting a slit therealong, the slit configured to receive a respective one of the plurality of strips, and wherein the first side of each of the plurality of slabs faces the second side of another of the plurality of slabs, a respective one of the plurality of strips disposed within the slit of the first side of the respective slab and within the slit of the second side of the another respective slab, each of the plurality of extension members extending through a respective one of the plurality of strips. In one further embodiment, the structure further comprises a plurality of L-shaped corner members, each of the L-shaped corner members exhibiting a first end and a second end perpendicular to the first end, the slit of each of the plurality of slabs further configured to receive one of a first end and a second end of a respective one of the plurality of L-shaped corner members, wherein the at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, the first end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a first of the pair of first enclosure members and the second end of each of the plurality of L-shaped corner members disposed within the slit of the first side of a respective one of the plurality of slabs of a second of the pair of first enclosure members.

In another embodiment, the first enclosure member comprises: an outer layer exhibiting an inner face and an outer face opposing the inner face, the outer face of the first enclosure member comprising the outer face of the outer layer, the outer layer comprising the plurality of facade members and the plurality of facade securing elements; and an insulation layer exhibiting an inner face and an outer face opposing the inner face, the inner face of the insulation layer facing the inner face of the second enclosure member, the outer face of the insulation layer facing the inner face of the outer layer. In one further embodiment, the outer face of the insulation layer is in direct contact with the inner face of the outer layer.

In another further embodiment, the structure further comprises: a grid assembly disposed within the hardenable material; a plurality of securing members, each of the plurality of securing members disposed on a respective one of the plurality of extension members and juxtaposed with the insulation layer to secure the insulation layer to the outer layer; and wherein the grid assembly is secured to one of the plurality of extension members so as to separate the grid assembly from the insulation layer by at least a predetermined distance.

In one embodiment, the structure further comprises: a ceiling panel positioned over the second enclosure member; and a ceiling layer of hardenable material disposed on the ceiling panel, the insulation layer of the first enclosure member rising above the ceiling layer of hardenable material.

In another independent embodiment, a hardenable material construction method is provided, the method comprising: juxtaposing an outer face of a first enclosure member to a first outer support arm, the first outer support arm extending from a support frame; securing a first end of at least one support extension member to the first outer support arm; juxtaposing a first inner support arm to an outer face of a second enclosure member, the first inner support arm extending from a support frame; securing a second end of the at least one support extension member to the first inner support arm; and subsequent to the securing the at least one support extension member to the first inner support arm, placing hardenable material into the space defined between an inner face of the first enclosure member and an inner face of the second enclosure member, the inner face of the first enclosure member opposing the outer face of the first enclosure member and the inner face of the second enclosure member opposing the outer face of the second enclosure member, wherein the secured at least one support extension member extends through the first enclosure member and the second enclosure member.

In one embodiment, the method further comprises, prior to the placing: securing the first outer support arm to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the securing; and securing the first inner support arm to the first extension arm, the extension of the first inner support arm from the support frame responsive to the securing. In one further embodiment, the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to the placing: securing a second outer support arm to a second extension arm extending from the support frame; and securing a second inner support arm to the second extension arm, wherein the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of the plurality of support extension members secured to the second inner support arm.

In one embodiment, the method further comprises, prior to the placing: securing a first end of each of a plurality of elongated strengthening arms to the first inner support arm; and securing a second end of each of the plurality of elongated strengthening arms to the support frame. In another embodiment, the distance between the support frame and the second enclosure member is 60-120 centimeters.

In one embodiment, the distance between the support frame and the second enclosure member is 80-100 centimeters. In another embodiment, the method further comprises, prior to the placing, extending a plurality of free extension members through the first enclosure member and the second enclosure member, wherein the extended free extension members are not secured to the first inner support arm or to the first outer support arm.

In one embodiment, the first inner support arm extends across the entirety of the outer face of the second enclosure member, and wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member. In another embodiment, the method further comprises: a) positioning a first side of each of a plurality of slabs to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof, the first side and second side of each of the plurality of slabs exhibiting a slit configured to receive a respective one of a plurality of strips; b) disposing a respective one of the plurality of strips within the slit of the first side of each of the plurality of slabs and the slit of the second side of the respective another slab; and c) inserting each of the at least on support extension member through a respective one of the plurality of strips, wherein the first enclosure member is formed responsive to steps a-b.

In one further embodiment, the method further comprises disposing each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, within the slit of the first side of a first of the plurality of slabs and within the slit of the first side of a second of the plurality of slabs.

In one embodiment, the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to the placing, inserting each of the plurality of support extension members through a respective one of a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of a plurality of facade members, wherein the first enclosure member comprises the plurality of facade members. In another embodiment, the method further comprises, prior to the placing: d) positioning an outer face of an insulation layer to face an inner face of an outer layer so as to form the first enclosure member, wherein the outer layer exhibits an outer face opposing the inner face thereof, the outer face of the first enclosure member comprising the outer face of the outer layer, and wherein the insulation layer exhibits an inner face opposing the outer face thereof, the inner face of the first enclosure member comprising the inner face of the insulation layer.

In one further embodiment, step d comprises positioning the outer face of the insulation layer to be in direct contact with the inner face of the outer layer. In another further embodiment, the method further comprises, prior to the placing: disposing a grid assembly within the space defined between the first enclosure member and the second enclosure member; securing the insulation layer to the outer layer with a plurality of securing members, each of the plurality of securing members disposed on a respective one of the plurality of extension members; and securing the grid assembly to one of the plurality of extension members so as to separate the grid assembly from the insulation layer by at least a predetermined distance.

Additional features and advantages of the invention will become apparent from the following drawings and description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings in which like numerals designate corresponding elements or sections throughout.

With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:

FIGS. 1A-1B illustrate various high level views of a temporary hardenable material construction apparatus comprising freestandable support frames, according to certain embodiments;

FIG. 1C illustrates a high level perspective view of the temporary hardenable material construction apparatus of FIGS. 1A-1B further comprising hardenable material, according to certain embodiments;

FIG. 1D illustrates a high level perspective view of a wall of the hardenable material of FIG. 1C, without the freestandable support frames of FIGS. 1A-1B, according to certain embodiments;

FIGS. 2A-2B illustrate various high level views of an enclosure member comprising a plurality of slitted slabs and a plurality of strips disposed therewithin, according to certain embodiments;

FIG. 2C illustrates a high level view of a slab of FIGS. 2A-2B, according to certain embodiments;

FIG. 2D illustrates a high level view of a strip of FIGS. 2A-2B, according to certain embodiments;

FIG. 2E illustrates a high level view of a temporary hardenable material construction apparatus comprising the enclosure member of FIGS. 2A-2B, according to certain embodiments;

FIG. 2F illustrates a high level view of the temporary hardenable material construction apparatus of FIG. 2E, further comprising an insulation layer, according to certain embodiments;

FIG. 2G illustrates a high level view of a portion of the temporary hardenable material construction apparatus of FIG. 2E, according to certain embodiments;

FIG. 2H illustrates a high level view of an L-shaped corner member, according to certain embodiments;

FIG. 2I illustrates a high level view of a pair of perpendicularly positioned enclosure members of FIGS. 2A-2B, according to certain embodiments;

FIGS. 3A-3D illustrate various high level views of a temporary hardenable material construction apparatus further comprising a pair of grid assemblies and a double layer enclosure member, according to certain embodiments;

FIG. 4 illustrates a high level schematic top view of a temporary hardenable material construction apparatus comprising a spiral staircase, according to certain embodiments;

FIGS. 5A-5E illustrate various high level views of a temporary hardenable material construction apparatus comprising a ceiling panel, according to certain embodiments;

FIG. 5F illustrates a high level perspective view of a temporary hardenable material construction apparatus in an advanced stage of construction, according to certain embodiments;

FIG. 5G illustrates a high level perspective view of a freestandable support frame configured with separate upper and lower sections, according to certain embodiments;

FIGS. 6A-6C illustrate various high level flow charts of a first hardenable material construction method, according to certain embodiments;

FIGS. 7A-7I illustrates various high level views of various stages of construction using a temporary hardenable material construction apparatus comprising support structures, according to certain embodiments; and

FIGS. 8A-8B illustrate various high level flow charts of a second hardenable material construction method, according to certain embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

FIG. 1A illustrates a high level perspective view of a temporary hardenable material construction apparatus 10 and FIG. 1B illustrates a high level side view of temporary hardenable material construction apparatus 10, FIGS. 1A-1B being described together.

Temporary hardenable material construction apparatus 10 comprises: a plurality of freestandable support frames 20, each exhibiting a first face 22, a second face 24 opposing first face 22, a plurality of receiving members 25 (not shown) extending across first face 22, a base portion 26, a top portion 27 opposing base portion 26, a first side 28 and a second side 29 opposing first side 28; a plurality of freestandable support frames 30, each exhibiting a first face 32, a second face 34 opposing first face 32, a plurality of receiving members 35 extending across first face 32, a base portion 36, a top portion 37 opposing base portion 36, a first side 38 and a second side 39 opposing first side 38; a plurality of extension members 40, each exhibiting a first end 42 and a second end 44 opposing first end 42; an enclosure member 50, exhibiting an inner face 52 and an outer face 54 opposing inner face 52; and an enclosure member 60, exhibiting an inner face 62 and an outer face 64 opposing inner face 62.

The term ‘freestandable’, as used herein, means that the support frame is able to stand on its own when placed on a surface without any additional supports securing it to another support structure or the ground. In one embodiment, each freestandable support frame 20 and 30 is constituted of any of, or a combination of, wood, plastic, metal or other polymers such as PVC and polycarbonate. In one embodiment, freestandable support frames 20 and 30 are each reusable frames. Receiving members 25, 35 of each respective freestandable support frame 20, 30 are illustrated as extending horizontally across respective first face 22, 32 thereof, however this is not meant to be limiting in any way. In another embodiment, receiving members 25, 35 extend vertically across the respective first face 22, 32, without exceeding the scope. In yet another embodiment, receiving members 25, 35 of each respective freestandable support frame 20, 30 are provided as a single board covering the respective first face 22, 32, without exceeding the scope.

First freestandable support members 20 and second freestandable support members 30 are each illustrated as being generally rectangular shaped, however this is not meant to be limiting in any way. Particularly, first freestandable support members 20 and second freestandable support members 30 are shaped in accordance to the shapes of enclosure member 50 and enclosure member 60, which can be provided in any shape according to the construction plans.

First side 28 and second side 29 of each freestandable support frame 20 extends from first face 22 to second face 24 and from base portion 26 to top portion 27. In one embodiment, first sides 28 and second sides 29 are each open, i.e. a person can walk therethrough. In another embodiment, base portion 26 of each freestandable support frame 20 is a generally flat and closed surface. In one embodiment, the distance between first face 22 and second face 24 of each freestandable support frame 20 is about 120 centimeters. Particularly, the distance between first face 22 and second face 24 is arranged such that two people can both work side by side within a single freestandable support frame 20. In another embodiment, the distance between first side 28 and second side 29 of each freestandable support frame 20 is about 60 centimeters. First side 38 and second side 39 of each freestandable support frame 30 extends from first face 32 to second face 34 and from base portion 36 to top portion 37. In one embodiment, the distance between first face 32 and second face 34 of each freestandable support frame 30 is at least 60 centimeters, optionally about 60 centimeters. In another embodiment, the distance between first side 38 and second side 39 of each freestandable support frame 30 is at least 120 centimeter, optionally about 120 centimeters. These dimensions allow for freestandable support frames 20, 30 to have a wide enough base to support themselves to be freestandable while also allowing a comfortable work space therein. In one non-limiting embodiment, the distance between base portion 26 and top portion 27, and the distance between base portion 36 and top portion 37, is at least 2 meters, optionally at least 2.7 meters, so as to allow the construction of a building wall. In one embodiment, each of first faces 22 and 32, second faces 24 and 34, base portions 26 and 36, top portions 27 and 37, first sides 28 and 28, and second sides 29 and 39 are generally rectangular.

As will be described below, in one embodiment each extension member 40 exhibits a plurality of grooves. Enclosure member 50 is positioned in parallel with enclosure member 60 such that a space 70 is defined between inner face 52 of enclosure member 50 and inner face 62 of enclosure member 60. Thus, inner face 52 is defined as the face of enclosure member 50 which faces, and defines, space 70 and outer face 54 is defined as the face of enclosure member 50 which faces away from space 70. Similarly, inner face 62 is defined as the face of enclosure member 60 which faces, and defines, space 70 and outer face 64 is defined as the face of enclosure member 60 which faces away from space 70. As will be described below, a hardenable material is arranged to be poured into space 70.

First face 22 of each freestandable support frame 20 is juxtaposed with outer face 54 of enclosure member 50 and in one embodiment is flush therewith. As illustrated, first face 22 of each freestandable support frame 20 is substantially completely covered by outer face 54 of enclosure member 50. In one embodiment, as illustrated, first face 22 is rectangular shaped, with the sides of first face 22 which are defined by first side 28 and second side 29 being longer than the sides of first face 22 which are defined by base portion 26 and top portion 27. First side 28 of each freestandable support frame 20 faces second side 29 of an adjacently positioned freestandable support frame 20 so as to form a row of freestandable support frames 20. In one embodiment, each freestandable support frame 20 is secured to an adjacent freestandable support frame 20. First face 32 of each freestandable support frame 30 is juxtaposed with outer face 64 of enclosure member 60 and in one embodiment is flush therewith. As illustrated, first face 32 of each freestandable support frame 30 is substantially completely covered by outer face 64 of enclosure member 60. In one embodiment, as illustrated, first face 32 is rectangular shaped, with the sides of first face 32 which are defined by first side 38 and second side 39 being longer than the sides of first face 32 which are defined by base portion 36 and top portion 37. First side 38 of each freestandable support frame 30 faces second side 39 of an adjacently positioned freestandable support frame 30 so as to form a row of freestandable support frames 30. In one embodiment, each freestandable support frame 30 is secured to an adjacent freestandable support frame 30.

Each extension member 40 extends through enclosure member 50, space 70 and enclosure member 60 such that first end 42 of each extension member 40 extends past outer face 54 of enclosure member 50 and second end 44 of each extension member 40 extends past outer face 64 of enclosure member 60. Additionally, first end 42 of each extension member 40 is secured to a receiving member 25 of a respective one of freestandable support frames 20. In one embodiment, where freestandable support frames 20 are constituted of wood or plastic, first end 42 extends through the respective receiving member 25 and is secured thereto on one or both sides thereof. In another embodiment, where freestandable support frames 20 are constituted of metal, first end 42 is welded to the respective receiving member 25. Additionally, second end 44 of each extension member 40 is secured to a receiving member 35 of a respective one of freestandable support frames 30. In one embodiment, where freestandable support frames 30 are constituted of wood or plastic, second end 44 extends through the respective receiving member 35 and is secured thereto on one or both sides thereof. In another embodiment, where freestandable support frames 30 are constituted of metal, second end 44 is welded to the respective receiving member 35. In one embodiment, 24 extension members 40 are secured to each freestandable support frame 20.

In one embodiment, as will be described further below in relation to temporary hardenable material construction apparatus 300, a steel grid assembly may be disposed within space 70. In another embodiment, water and sanitation pipes and electric wiring may be disposed within space 70 prior to pouring the hardenable material described below.

Temporary hardenable material construction apparatus 10 is illustrated and described as comprising a plurality of freestandable support frames 20 and a plurality of freestandable support frames 30, however this is not meant to be limiting in any way and a single freestandable support frame 20 and a single freestandable support frame 30 may be provided without exceeding the scope. Advantageously, utilizing a plurality of freestandable support frames 20, 30 allows for the use of smaller support frames which are light, easily portable and do not require a complex manufacturing process.

As illustrated in FIG. 1C, a hardenable material 80 is poured into space 70. In one embodiment, hardenable material 80 comprises concrete. In another embodiment, hardenable material 80 comprises any fluidic material which hardens. For clarity, FIGS. 1A-1C are illustrated where space 70 is open at the ends of enclosure members 50, 60, however temporary hardenable material construction apparatus 10 is particularly contemplated as comprising means for containing hardenable material 80 within space 70. In one embodiment, as will be described below in relation to temporary hardenable material construction apparatus 500, four perpendicular spaces 70 are constructed thereby creating a single enclosed space for hardenable material 80. In another embodiment, the ends of space 70 are covered with material to hold hardenable material 80 therein.

As illustrated in FIG. 1D, after hardenable material 80 is poured into space 70, and is allowed to harden, freestandable support frames 20, 30 are removed. First end 42 and second end 44 of each extendable member 40 is then sawed off. A wall 90 is thus provided, comprising enclosure members 50, 60 and hardened hardenable material 80. Advantageously, the hardened hardenable material 80 doesn't have to be covered with additional wall sections, since enclosure members 50, 60 are already attached thereto. However, in another embodiment, one or both of enclosure members 50, 60 can be removed after hardenable material 80 hardens, so the hardened hardenable material 80 can be covered with other materials or left exposed. As will be described further below, in one embodiment enclosure member 50 is secured to the hardened hardenable material 80 by extending members 40 and enclosure member 60 is secured to the hardened hardenable material by protrusions extending therefrom. Further advantageously, freestandable support frames 20, 30 can be reused since they do not need to be disassembled to be removed from wall 90.

Temporary hardenable material construction apparatus 10 has been describe and illustrated as comprising one or more freestandable support frames 20 and one or more freestandable support frames 30, however this is not meant to be limiting in any way. In another embodiment, freestandable support frames 30 are not provided and extension members 40 are secured to freestandable support frames 20. In another embodiment, freestandable support frames 20 are not provided and extension members 40 are secured to freestandable support frames 30.

In one embodiment (not shown), enclosure member 50 comprises: a plurality of facade members; and a plurality of facade securing elements, each of the plurality of facade securing elements secured to a perimeter of a respective one of the plurality of facade members. First end 42 of each extension member 40 extends through a respective one of the plurality of facade securing elements. The facade members are members which form a facade, such as stones. The facade members can exhibit any shape and dimensions which are desired. Optionally, the perimeter of each facade member, i.e. the sides thereof, exhibit a plurality of insertion holes, each the insertion holes containing a respective one of the plurality of facade securing elements. The facade securing elements are each designed to exhibit an opening to receive therethrough an extension member 40. Enclosure member 50 is formed by positioning the facade members along a single plane, each facade member optionally secured to an adjacent facade member with appropriate material, such as mortar.

FIG. 2A illustrates a high level perspective view of a portion of an enclosure member 100 comprising a plurality of slabs 110 and a plurality of strips 120. FIG. 2B illustrates a full high level perspective view of enclosure member 100. FIG. 2C illustrates a high level perspective view of a slab 110. FIG. 2D illustrates a high level perspective view of a strip 120. FIG. 2E illustrates a high level perspective view of a temporary hardenable material construction apparatus 200. FIG. 2F illustrates a high level perspective view of temporary hardenable material construction apparatus 200 further comprising an insulation layer. FIG. 2G illustrates a high level perspective view of temporary hardenable material construction apparatus 200 without freestandable support frames for clarity. FIG. 2H illustrates a high level perspective view of an L-shaped corner member 210. FIG. 2I illustrates a high level perspective view of a pair of perpendicularly positioned enclosure members 100 secured to each other with a plurality of L-shaped corner members 210. FIGS. 2A-21 will be described together.

Each slab 110 exhibits: a first face 111; a second face 112 opposing first face 111; a first side 113 extending from first face 111 to second face 112; a second side 114 extending from first face 111 to second face 112 and opposing first side 113; a third side 115 extending from first face 111 to second face 112 and from first side 113 to second side 114; and a fourth side 116 extending from first face 111 to second face 112 and from first side 113 to second side 114, fourth side 116 opposing third side 115. First side 113 and second side 114 of each slab 110 exhibits a slit 130 extending therealong from third side 115 to fourth side 116. Slits 130 are each configured to receive a respective strip 120. Particularly, the width of slit 130 is configured to be greater than, or equal to, the thickness of each strip 120.

As illustrated in FIGS. 2A-2B, enclosure member 100 is formed of a plurality of columns of slabs 110. Particularly, each column of slabs 110 comprises a plurality of slabs 110 on top of each other such that first side 113 of each slab 110 faces second side 114 of an adjacent slab 110. Columns of slabs 110 are positioned next to each other to form rows of slabs 110 such that third side 115 of each slab 110 faces fourth side 116 of an adjacent slab 110. Each strip 120 is disposed within slit 130 of first side 113 of a respective slab 110 and within slit 130 of second side 114 of the adjacent slab 110 which faces the respective first side 113. In one embodiment, the length of each strip 120 is greater than the length of each slit 130 such that each strip 120 is disposed within slits 130 of slabs 110 from more than one column. In another embodiment, the length of each strip 120 is not greater than the length of each slit 130, however strips 120 are disposed within slits 130 such that each strip 120 is disposed within slits 130 of slabs 110 from more than one column. As illustrated in FIG. 2D, each strip 120 exhibits one or more holes.

Temporary hardenable material construction apparatus 200 of FIG. 2E is in all respects similar to temporary hardenable material construction apparatus 10, with the exception that enclosure member 50 is replaced with enclosure member 100. As illustrated in FIG. 2G, where freestandable members 20, 30 are not shown for simplicity, extension members 40 extend through holes 140 of strips 120. In one embodiment, after insertion through holes 140, extension members 40 are each welded to the respective strip 120. In another embodiment, extension members 40 each comprise a plurality of grooves and a nut is threaded onto each extension member 40 on one or both sides of the respective strip 120. Securing enclosure member 100 with nuts, or by welding, keeps enclosure member 100 from sliding along extension members 40.

In one embodiment, the depth of each slit 130 is configured to be less than half the width of each strip 120 such that when strip 120 is disposed within slits 130 of the respective adjacent slabs 110, slabs 110 do not meet and there is a space 135 between first side 113 of a first of the adjacent slabs 110 and second side 114 of the second of the adjacent slabs 110, the respective extension member 40 extending through the space 135 between the respective first side 113 and second side 114.

In another embodiment, when forming enclosure member 100, a first slab 110 is positioned and a strip 120 is disposed within slit 130 of first side 113 thereof. At least two extension members 40 are then inserted through respective holes 140 of the disposed strip 120. An additional slab 110 is then position on top of the first slab 110 such that the disposed strip 120 is additionally disposed within second side 114 of the additional slab 110, the separation of the adjacent slabs 110 being maintained by the inserted extension members 40.

In order to add a window or door within the wall, a predetermined number of slabs 110 are left out of enclosure member 100. In place of the left out slabs 110, a frame is inserted which extends through space 70 thereby not allowing hardenable material to enter the space surrounded by the inserted frame.

After hardenable material is poured into space 70, freestandable support frames 20, 30 are removed and first and second ends 42, 44 of each extension member 40 is sawed off. In one embodiment, the space between each adjacent pair of slabs 110 is filled with a filling material.

In one embodiment, as illustrated in FIG. 2F, an insulation layer 150 is further provided, juxtaposed with second faces 112 of slabs 110, as will be described below in relation to temporary hardenable material construction apparatus 300.

As illustrated in FIG. 2I, a pair of enclosure members 100 are illustrated being positioned perpendicularly to each other. A plurality of L-shaped corner members 210, illustrated in FIG. 2H, are arranged to connect the pair of enclosure members 100. Particularly, each L-shaped corner member 210 exhibits a first half 212 and a second half 214, second half 214 being perpendicular to first half 212. First half 212 of each L-shaped corner member 210 is disposed within respective slits 130 of a first of the pair of perpendicularly positioned enclosure members 100 and second half 214 of each L-shaped corner member 210 is disposed within respective slits 130 of the second of the pair of perpendicularly positioned enclosure members 100. Preferably, L-shaped corner members 210 are each formed as a single piece, i.e. not two separate pieces which are welded or screwed together. Therefore, when hardenable material is poured into space 70 defined by both enclosure members 100, L-shaped corner members 210 secure enclosure members 100 to each other so as not separate responsive to the pressure applied by the poured hardenable material.

In another embodiment (not shown), slabs 110 are provided with slits within first face 111, the slits being of appropriate shape and size such that a strip 120, or a portion thereof, can be inserted therein and secured to slab 110. Extension members 40 are secured to strips 120, optionally by welding. Since the slits are within first face 111, thereby facing space 70, and not between adjacent slabs 110, extension members 40 do not interfere with the placement of slabs 110 and the rows of slabs 110 can be flush with each other.

FIG. 3A illustrates a perspective view of a temporary hardenable material construction apparatus 300; and FIG. 3B illustrates a side view of temporary hardenable material construction apparatus 300, FIGS. 3A-3B being described together. Temporary hardenable material construction apparatus 300 is in all respects similar to temporary hardenable material construction apparatus 10, further comprising a pair of grid assemblies 310 and a plurality of securing members 320. Additionally, enclosure member 50 is replaced with an enclosure member 330.

Enclosure member 330 comprises: an outer layer 340 exhibiting an inner face 342 and an outer face 344 opposing inner face 342; and an insulation layer 350 exhibiting an inner face 352 and an outer face 354. In one embodiment, outer face 354 of insulation layer 350 is in direct contact with inner face 342 of outer layer 340, i.e. there is no plaster between insulation layer 350 and outer layer 340. As a result, when condensation trapped between insulation layer 350 and outer layer 340 turns into droplets during the night, the droplets will slide down inner face 342 of outer layer 340 and outer face 354 of insulation layer 350 until reaching the ground. Advantageously, the condensation does not remain between insulation layer 350 and outer layer 340 and thus will not expand during the day and cause damage and deformations of outer layer 340.

In one embodiment, as described above in relation to temporary hardenable material construction apparatus 200, outer layer 340 comprises a plurality of slitted slabs coupled together with strips disposed within the slits of the slabs. In one embodiment, insulation layer 350 comprises a panel of insulating material, such as polystyrene. In another embodiment, insulation layer 350 comprises a hardenable insulating material which is sprayed onto inner face 342 of outer layer 340, thereby forming a hardened insulation layer over inner face 342. Inner face 342 of outer layer 340 faces outer face 354 of insulation layer 350. Inner face 352 of insulation layer 350 faces inner face 62 of enclosure member 60, space 70 being defined by inner face 62 of enclosure member 60 and inner face 352 of insulation layer 350.

Each grid assembly 310 is constructed of a grid of horizontal and vertical bars, preferably steel bars. Each grid assembly 310 is separated from a respective one of enclosure member 330 and enclosure member 60 by at least a predetermined distance. Preferably, the predetermined distance is 1.5 centimeters. A pair of separation members may be attached to each extension member 40, optionally screwed thereon. The separation members are arranged to keep grid assemblies 310 from becoming too close to the respective enclosure member 330, 60, to ensure that each grid assembly 310 will be completely covered by the poured hardenable material and to thereby retard corrosion of the grid bars. In the event that grid assemblies 310 become too close to the respective enclosure members 330, 60, the poured hardenable material may not separate between them.

Each securing member 320 is attached to a respective one of extension members 40, preferably screwed thereon, and disposed on inner face 352 of insulation layer 350. Securing members 320 are arranged to press insulation layer 350 against outer layer 340 to secure insulation layer 350 to outer layer 340 to further maintain the predetermined distance between insulation layer 350 and the adjacent grid assembly 310. In one embodiment (not shown), an additional securing member is attached to each extension member 40 and disposed on inner face 62 of enclosure member 60 to secure enclosure member 60 to freestandable support frames 30 while maintaining smooth contact therewith. Particularly, in the event that a nut is screwed onto an extension member 40 and pressed against outer wall 64 of enclosure member 60, the additional securing member is arranged to secure enclosure member 60 so as not to accidentally be pushed or distorted from pressing the nut too much into outer wall 64.

In one embodiment, grid assemblies 310 are welded to at least some of extension members 40 at the predetermined distance from the respective one of enclosure members 330, 60.

In addition, each grid assembly 310, which may be positioned to be substantially parallel to enclosure members 60 and 330 and substantially perpendicular to extension members 40, may be welded to a plurality of extension members 40.

More particularly, bars of each grid assembly 310 may be welded to the extension members 40 by a weld formation to define a plurality of rectilinear hoops H. Each hoop H is typically defined by eight welds: (1) weld j at the junction of a first extension member 40 and a first vertical bar of grid assembly 310, (2) weld k at the junction of the first extension member and a second vertical bar of grid assembly 310 which is transversally spaced from the first extension member, (3) weld 1 at the junction of a second extension member located directly below the first extension member and the first vertical bar, (4) weld m at the junction of the second extension member and the second vertical bar, (5) weld j′ (not shown) at the junction of a third extension member being at the same height as, and longitudinally spaced from, the first extension member and a third vertical bar longitudinally spaced from the first vertical bar, (6) weld k′ (not shown) at the junction of the third extension member and a fourth vertical bar transversally spaced from the third extension member, (7) weld l′ (not shown) at the junction of a fourth extension member located directly below the third extension member and the third vertical bar, and (8) weld m′ (not shown) at the junction of the fourth extension member and the fourth vertical bar.

Similarly, a hoop may be defined by a weld at the junction of an extension member and a horizontal bar of grid assembly 310. Following the formation of a plurality of hoops H and the pouring and setting of the hardenable material, a reinforced wall structure of superior impact resistance is produced. Each hoop H confines a corresponding volume of the hardened material, particularly concrete, and significantly increases the strain capacity, often as much as ten-fold. The hoops H act to restrain dilation of the hardened material as it is loaded in compression, and this confining action leads to increased compressive strength and strain capacity. Indeed, tests conducted by the Applicant indicated that the impact resistance of the hoop-reinforced wall structure of the present invention has an impact resistance of greater than 40% relative to prior art wall structures that are reinforced only by a grid assembly, and not by hoops.

It will be appreciated that improved impact resistance will be realized even when a hoop H is not contiguous with an adjacent hoop, although optimum impact resistance is achieved when a wall structure includes continuous and contiguous hoops.

The hoops generally follow the shape of the wall structure, whether rectilinear or curvilinear, although the hoops may assume a different shape than the wall structure, depending on the type of grid assembly used and the relative placement of the grid assembly. Following placement of the grid assembly, a reinforcement splice or crosstie may be employed to connect between an extension member and the grid assembly if there is a gap therebetween.

In another embodiment, as shown in FIG. 3C, a prebent grid assembly 370 may be employed. A planar grid assembly is preferably bent at a factory by a dedicated bending machine to produce prebent grid assembly 370, but may be also be bent in situ. Prebent grid assembly 370 has a rectilinear configuration with two longitudinal portions 372 and 373 and three transversal portions 376-378. The rectilinear configuration simplifies deployment of the grid assembly in the space between the inner and outer standable support frames, without need of bracing or the like to maintain the grid assembly in an upright position by virtue of the stable rectilinear configuration. The first longitudinal portion 372 which is the longest longitudinal portion and the first transversal portion 376 which is the longest transversal portion are adjacent and substantially perpendicular to each other.

The second transversal portion 377 which is adjacent and substantially perpendicular to the second longitudinal portion 373 and the third transversal portion 378 which is adjacent and substantially perpendicular to the first longitudinal portion 372 may overlap each other. For example, first longitudinal portion 372 has a length of 120 cm and first transversal portion 376 has a length of 15 cm.

As shown in FIG. 3D, the use of prebent grid assembly 370 advantageously allows the reinforced wall structure to have an increased number of hoops for a given wall thickness. Extension members are welded to portions of prebent grid assembly 370 to define each hoop.

Prebent grid assembly 370 is positioned in the space between the inner and outer standable support frames, and of course additional longitudinally spaced prebent grid assemblies may also be positioned in the space between the inner and outer standable support frames.

A three-dimensional hoop K is typically defined by eight welds: (1) weld s at the junction of first extension member 40A and first longitudinal portion 372 of a first bent bar of the grid assembly, (2) weld t at the junction of first extension member 40A and second longitudinal portion 373 of the first bent bar, (3) weld s′ (not shown) at the junction of a second extension member located directly below first extension member 40A and first longitudinal portion 372 of a second bent bar located below the first bent bar, (4) weld t′ at the junction of the second extension member and second longitudinal portion 373 of the second vertical bar, (5) weld u at the junction of third extension member 40C being at the same height as, and longitudinally spaced from, first extension member 40A and first longitudinal portion 372 of a first bent bar, (6) weld v at the junction of third extension member 40C and second longitudinal portion 373 of the first bent bar, (7) weld u′ (not shown) at the junction of a fourth extension member located directly below third extension member 40C and first longitudinal portion 372 of the second bent bar, and (8) weld v′ (not shown) at the junction of the fourth extension member and second longitudinal portion 373 of the second bent bar. A vertical bar of prebent grid assembly 370 generally extends between each pair of welds s-s′, t-t′, u-u′ and v-v′ to complete the three-dimensional hoop K.

An additional hoop L of smaller dimensions may be formed from first extension member 40A between welds s and t, first transversal portion 376, first longitudinal portion 372 between first transversal portion 376 and weld s, and second longitudinal portion 373 between first transversal portion 376 and weld t. Tests conducted by the Applicant indicated that the impact resistance of a hoop reinforced wall structure that is additionally reinforced by a prebent grid assembly has an impact resistance of greater than 60% relative to prior art wall structures that are reinforced only by a grid assembly, and not by hoops. A wall structure having such a high impact resistance is able to remain intact after being impacted by a projectile having a speed of up to 2500 kilometer/hr.

FIG. 4 illustrates a high level schematic diagram of a high level top view of a portion of a temporary hardenable material construction apparatus 400. Temporary hardenable material construction apparatus 400 comprises a pair of temporary hardenable material construction apparatuses 300 positioned perpendicularly to each other. Temporary hardenable material construction apparatus 400 further comprises a spiral staircase 410 at a corner 420 where perpendicularly positioned temporary hardenable material construction apparatuses 300 meet. As illustrated, a space exists between the ultimate freestandable support frame 20 of a first of the pair of temporary hardenable material construction apparatuses 300 and the ultimate freestandable support frame 20 of the second of the pair of temporary hardenable material construction apparatuses 300 at corner 420, spiral staircase 410 positioned within the empty space of corner 420. Spiral staircase 410 is arranged to rise to the height of top portions 27 of freestandable support frames 20 so that a second level of freestandable support frames 20, which are disposed on top of the first level of freestandable support frames 20, is easily accessible. If additional levels of freestandable support frames 20 are provided, as will be described further below, spiral staircase 410 is arranged to rise to the highest level of freestandable support frames 20. For simplicity, only a portion of each temporary hardenable material construction apparatus 300 is illustrated. Additionally, for simplicity, grid assemblies 310 and securing members 320 are not illustrated.

FIG. 5A illustrates a high level perspective view of a portion of a temporary hardenable material construction apparatus 500. FIG. 5B illustrates a high level side view of the portion of temporary hardenable material construction apparatus 500 of FIG. 5A. FIG. 5C illustrates a high level perspective view of temporary hardenable material construction apparatus 500. FIG. 5D illustrates a high level side view of temporary hardenable material construction apparatus 500. FIG. 5E illustrates a high level top view of temporary hardenable material construction apparatus 500. FIG. 5F illustrates a high level perspective view of a temporary hardenable material construction apparatus 600. FIGS. 5A-5F are described together. Temporary hardenable material construction apparatus 500 is in all respects similar to temporary hardenable material construction apparatus 300 with the addition of: a plurality of freestandable support frames 510; a ceiling panel 520 exhibiting a first face 521, a second face 522 opposing first face 521, a first side 523 extending from first face 521 to second face 522, a second side 524 opposing first side 523 and extending from first face 521 to second face 522, a third side 525 perpendicular to first side 523 and extending from first face 521 to second face 522, and a fourth side 526 opposing third side 525 and extending from first face 521 to second face 522; and a plurality of hardenable material securing members 530. For clarity, extension members 40, grid assemblies 310 and securing members 320 are not shown. In one embodiment, ceiling panel 520 comprises a drywall panel. Additionally, as illustrated in FIGS. 5C-5D, temporary hardenable material construction apparatus 500 comprises four enclosure members 330 and four enclosure members 60, space 70 being defined between inner faces 52 of enclosure members 330 and inner faces 62 of enclosure members 60.

Freestandable support frames 510 are in all respects similar to freestandable support frames 20 and base portion 26 of each freestandable support frame 510 is positioned on top of top portion 27 of a respective freestandable support frame 20 such that freestandable support frames 510 are supported by freestandable support frames 20. Enclosure member 330 extends from base portions 26 of freestandable support frames 20 to top portions 27 of freestandable support frames 510.

Second face 522 of ceiling panel 520 is disposed on top portions 37 of freestandable support frames 30 and on enclosure member 60. Particularly, first side 523 of ceiling panel 520 meets the plane defined by inner face 62 of enclosure member 60, ceiling panel 520 extending away from freestandable support frames 30. As illustrated in FIGS. 5C and 5D, ceiling panel 520 is disposed on four rows of freestandable support frames 30. Each of a first set of hardenable material securing members 530 extends vertically from within ceiling panel 520 to a point above first face 521. In one embodiment, each hardenable material support member 530 extends about 12 centimeters above first face 521. In another embodiment, each hardenable material support member 530 is 6-8 millimeters thick. In one embodiment, hardenable material securing members 530 are spaced apart from each other at distances of about 60 centimeters. In another embodiment, each hardenable material support member 530 comprises a screw. Similarly, each of a second set of hardenable material securing members 530 extends horizontally from within enclosure member 60 to a point within space 70, displaced from inner face 62 of enclosure member 60. In one embodiment, wooden beams, and optionally an additional wooden panel, are disposed between ceiling panel 520 and top portions 37 of freestandable support frames 30.

As described above in relation to temporary hardenable material construction apparatus 400, a spiral staircase 410 is positioned at each corner of the rows of freestandable support frames 20 such that freestandable support frames 510 are easily accessible.

Hardenable material 80 is poured onto ceiling panel 520. Hardenable material 80, which as described above is a fluid material, such as concrete, spills over first, second, third and fourth sides 523, 524, 525, 526 of ceiling panel 520 into space 70 formed between the four second enclosure members 60 and four enclosure members 330. As a result, four walls and a ceiling are formed as a single block of hardenable material 80, which gradually hardens. Hardenable material securing members 530 are arranged to secure ceiling panel 520 and each of enclosure members 60 to hardenable material 80 after hardening. Advantageously, in the embodiment where ceiling panel 520 and enclosure members 60 each comprise a drywall panel, the drywall panels are directly attached to the hardened hardenable material, without the use of plaster.

After pouring hardenable material 80, a second floor can be built, as illustrated in temporary hardenable material construction apparatus 600 of FIG. 5F, which represents temporary hardenable material construction apparatus 500 after hardenable material 80 is poured. Particularly, temporary hardenable material construction apparatus 600 is in all respects similar to temporary hardenable material construction apparatus 500, with the exception that freestandable support frames 30 are replaced with a plurality of freestandable support frames 610. Additionally, an enclosure member 620 is provided. Freestandable support frames 610 are in all respects similar to freestandable support frames 30, with the exception that base portions 36 of freestandable support frames 610 are positioned on top of hardenable material 80, over ceiling panel 520 and over the location of the previously positioned freestandable support frames 30. Enclosure member 620 is in all respects similar to enclosure member 60, with the exception that enclosure member 620 is positioned on top of hardenable material 80, over ceiling panel 520 and over enclosure member 60. As described above in relation to freestandable support frames 30, first face 32 of each freestandable support frame 30 is juxtaposed with outer face 64 of enclosure member 620. As described above in relation to enclosure members 50 and 60, a space 70 is defined between inner face 52 of enclosure member 330 and inner face 62 of enclosure member 620. A ceiling panel (not shown) can be positioned on top of freestandable support frames 610 and hardenable material 80 can be poured thereon, as described above in relation to temporary hardenable material construction apparatus 500. As described above, extension members 40 extend through enclosure member 330 and enclosure member 620 and are secured to freestandable support frames 510 and freestandable support frames 610.

In another embodiment shown in FIG. 5G, an inner freestandable support frame 630 is used to support ceiling panel 520. Temporary hardenable material construction apparatus 500 and 600 are applicable to freestandable support frame 630, the other aspects thereof applying with the exception of freestandable support frame 30, mutatis mutandis.

In order to facilitate its removal after ceiling panel 520 has been formed thereabove, inner freestandable support frame 630 is configured with separate upper section 632 and lower section 634, which may be identical, albeit oppositely oriented. To each upright 629 of upper section 632 and to an upright 631 of lower section 634 aligned therewith is positioned in abutting relation, and releasably secured thereto, a corresponding elongated connector 637, which may have a uniform width and be carefully positioned so as not to protrude into the space within which the hardenable material is to be poured.

Inner freestandable support frame 630 generally, but not necessarily, has the same dimensions as freestandable support frame 30. For example, a rectilinear inner freestandable support frame 630 has a height of 270 cm, a longitudinal dimension of 120 cm and a transversal dimension of 60 cm. This height is achievable by providing a void area of 30 cm between upper section 632 and lower section 634 and by releasably securing connector 637 having a length of 30 cm to the upright of both upper section 632 and lower section 634. As additional means for ensuring the structural strength of inner standable support frame 630, an insert 639 is received within the void area in such a way so as to contact and be in force transmitting relation with both upper section 632 and lower section 634. Insert 639 is releasably connected to connector 637.

After ceiling panel 520 has been formed and has hardened, each insert 639 is detached from its corresponding connector 637, after which the fasteners by which connectors 637 are secured to a corresponding pair of uprights 629 and 631 are released. As it is no longer connected to lower section 634, upper section 632 is therefore able to be easily removed from below the ceiling panel.

It will be appreciated that inner freestandable support frame 630 may be configured with any other number of interconnectable sections.

Although the above has been described in relation to freestandable support frames 20, 30, 510, 610 and 630 this is not meant to be limiting in any way. In another embodiment, freestandable support frames 20, 30, 510 and 610 can be replaced with support frames which are not freestandable without exceeding the scope.

FIG. 6A illustrates a high level flow chart of a hardenable material construction method. In stage 1000, a first enclosure member is positioned in parallel with a second enclosure member such that a space is defined between an inner face of the first enclosure member and an inner face of the second enclosure member. Optionally, the second enclosure member is formed of a drywall panel, optionally sealed with a liquid repelling material.

In stage 1010, a first freestandable support frame is juxtaposed with an outer face of the first enclosure member of stage 1000 or the outer face of the second enclosure member of stage 1000. The outer face of the first enclosure member opposes the inner face of the first enclosure member. The outer face of the second enclosure member opposes the inner face of the second enclosure member. First freestandable support frame extends from a first face to a second face, the first face thereof juxtaposed with the outer face of the first enclosure member. Optionally, the distance between the first face and the second face of the first freestandable support frame is about 120 centimeters. Optionally, a plurality of first freestandable support frames are each juxtaposed with the outer face of the first enclosure member, or the outer face the second enclosure member, the plurality of first freestandable support frames arranged in a row. Optionally, the first freestandable support frame exhibits an indentation in the first face thereof, the indentation arranged to receive a protruding portion of the first enclosure member of stage 1000.

In optional stage 1020, a second freestandable support frame is juxtaposed with an outer face of the second enclosure member of stage 1000, the outer face of the second enclosure member opposing the inner face of the second enclosure member. In such an embodiment, the first freestandable support frame of stage 1010 is juxtaposed with the outer face of the first enclosure member of stage 1000. Optionally, a plurality of second freestandable support frames are each juxtaposed with the outer face of the second enclosure member, the plurality of second freestandable support frames arranged in a row.

In stage 1030, at least one extension member is inserted through the first enclosure member and the second enclosure member such that a first end of the at least one extension member extends past the outer face of the first enclosure member of stage 1000 or a second end of the at least one extension member, opposing the first end thereof, extends past the outer face of the second enclosure member of stage 1000.

In stage 1040, the at least one extension member of stage 1030, optionally the first end thereof, is secured to the first freestandable support frame of stage 1010. Optionally, a plurality of extension members are each secured to a respective one of a plurality of first freestandable support frames. In optional stage 1050, the second end of the at least one extension member is secured to the second freestandable support frame of optional stage 1020. Optionally, a plurality of extension members are each secured to a respective one of a plurality of second freestandable support frames.

In stage 1060, subsequent to the securing the at least one extension member to the first and second freestandable support frame of stages 1040-1050, hardenable material is poured into the space defined between the first enclosure member and the second enclosure member of stage 1000.

In optional stage 1070, prior to the pouring hardenable material of stage 1060, an outer face of an insulation layer is positioned to face an inner face of an outer layer so as to form the first enclosure member of stage 1000. The outer layer exhibits an outer face opposing the inner face thereof, an outer face of the first enclosure member of stage 1000, opposing the inner face thereof, comprising the outer face of the outer layer. Additionally, the insulation layer exhibits an inner face opposing the outer face thereof, the inner face of the first enclosure member of stage 1000 comprising the inner face of the insulation layer. Optionally, the outer face of the insulation layer is positioned to be in direct contact with the inner face of the outer layer. Particularly, no plaster is disposed between the insulation layer and the outer layer.

In optional stage 1080, a grid assembly is disposed within the defined space of stage 1000. Additionally, the grid assembly is secured to one of a plurality of the extension members of stage 1030 so as to separate the grid assembly from the insulation layer of optional stage 1070 by at least a predetermined distance. In optional stage 1090, the insulation layer is secured to the outer layer with a plurality of securing members, each of the plurality of securing members disposed on a respective one of a plurality of the extension members of stage 1030.

FIG. 6B illustrates a high level flow chart of optional stages of forming the first enclosure of stage 1000 of FIG. 6A. In stage 2000, a first side of each of a plurality of slabs is positioned to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof. The first side and second side of each of the plurality of slabs exhibit a slit configured to receive a respective one of a plurality of strips. In stage 2010, a respective one of the plurality of strips of stage 2000 is disposed within the slit of the first side of each of the plurality of slabs of stage 2000 and the slit of the second side of the respective another slab.

In stage 2020, each of a plurality of the extension members of stage 1030 is inserted through a respective one of a plurality of facade securing elements, the facade securing elements each secured to one of a plurality of facade members. Optionally, each facade member comprises a slab of stage 2000 and each facade securing element comprises a strip of stage 2010. Optionally, the insertion through the first enclosure member of stage 1030 is responsive to the insertion through the plurality of facade securing elements.

In optional stage 2030, each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, is disposed within the slit of the first side of a first of the plurality of slabs of stage 2000 and within the slit of the first side of a second of the plurality of slabs.

FIG. 6C illustrates a high level flow chart of further optional stages of the hardenable material construction method of stages 1000-1090. In stage 3000, prior to the pouring hardenable material of stage 1060, a ceiling panel is positioned to be supported by an upper portion of the second freestandable support frame of stage 1020. In stage 3010, a third freestandable support frame is positioned on top of the first freestandable support frame. In stage 3020, the third freestandable support frame of stage 3010 is juxtaposed with the outer face of the first enclosure member, the insulation layer of the first enclosure member of optional stage 1070 rising above the positioned ceiling panel. In stage 3030, hardenable material is poured onto the ceiling panel, the pouring hardenable material into the space defined between the first enclosure member and the second enclosure member of stage 1060 responsive to the pouring hardenable material onto the positioned ceiling panel. The hardenable material spills from the ceiling panel into the defined space such that a single block of hardenable material is formed as a ceiling and walls.

In optional stage 3040, the positioned ceiling panel comprises a drywall panel with a plurality of hardenable material securing members inserted into the drywall panel such that each of the plurality of hardenable material securing members extend from within the drywall panel to a point above a face of the drywall panel.

FIGS. 7A-7I illustrates various high level views of various stages of construction using a temporary hardenable material construction apparatus 700, according to certain embodiments. Particularly, FIG. 7A illustrates a high level perspective view of a support structure 710 comprising: a support frame 720; a pair of extension arms 730, each exhibiting a first end 732 and a second end 734 opposing first end 732; a pair of inner support arms 740; and a pair of outer support arms 750. Support frame 720 comprises: a plurality of upper arms 760, each exhibiting a first end 762 and a second end 764 opposing first end 762; a plurality of lower arms 770, each exhibiting a first end 772 and a second end 774 opposing first end 772; a plurality of connection arms 780, each exhibiting a first end 782 and a second end 784 opposing first end 782; a base portion 790 exhibiting a first side 792, a second side 794, a third side 796 and a fourth side 798; and a top portion 800 exhibiting a first side 802, a second side 804, a third side 806 and a fourth side 808.

Upper arms 760 each extend downwards in a generally vertical direction from top portion 800 at first end 762 thereof and lower arms 770 each extend upwards in a generally vertical direction from base portion 790 at first end 772 thereof such that second end 764 of each upper arm 760 faces second end 774 of each lower arm 774, with an adjustable space 810 between them. First end 782 of each connection arm 780 is secured to a respective upper arm 760 and the respective second end 784 is secured to the opposing lower arm 770. In order to adjust the size of space 810, i.e. the distance between second ends 764 of upper arms 760 and second ends 774 of upper arms 770, upper arms 760 and lower arms 770 are respectively connected to connecting arms 780 at different points thereof. In one embodiment, base portion 790 is generally rectangular shaped with short opposing sides 792 and 794 and long opposing sides 796 and 798. First end 772 of each lower arm 770 is secured at a respective corner of the generally rectangular shaped base portion 790. In another embodiment, top portion 800 is generally rectangular shaped with short opposing sides 802 and 804 and long opposing sides 806 and 808. First end 762 of each upper arm 760 is secured at a respective corner of the generally rectangular shaped top portion 800. In one embodiment, the length of each of long sides 796, 798, 806 and 808 are at least 60 centimeters, optionally at least 80 centimeter and further optionally about 120 centimeters. In another embodiment, the length of each of short sides 792, 794, 802 and 804 is at least 60 centimeters. In one particular embodiment, the length of each of short sides 792, 794, 802 and 804 is about 60 centimeters and the length of each of long sides 796, 798, 806 and 808 is about 120 centimeters. As described above in relation to freestandable support frames 20 and 30, such dimensions allow for support frame 720 to be freestandable and further allows for two workers to simultaneously be inside support frame 720. In one embodiment, support frame 720 is bolted into the floor.

A first extension arm 730 extends from side 806 of top portion 800, at first end 732 thereof, and a second extension arm 730 extends from side 808 of top portion 800, at first end 732 thereof. In one embodiment, side 806 and first extension arm 730 form a single beam and side 808 and second extension arm 730 form a single beam. In one embodiment, the length of each extension arm 730 is no more than 150 centimeters such that support frame 720 can support inner support arms 740 and outer support arms 750, as will be described below. A first outer support arm 750 extends downward in a generally vertical direction from second end 734 of first extension arm 730 and a second outer support arm 750 extends downward in a generally vertical direction from second end 734 of second extension arm 730. A first inner support arm 740 extends downward in a generally vertical direction from a predetermined point of first extension arm 730 and a second inner support arm 740 extends downward in a generally vertical direction from a predetermined point of second extension arm 730. The distance between inner support arms 740 and outer support arms 750 is denoted 820, distance 820 being determined in accordance with the desired wall dimensions, as will be described below. In one non-limiting embodiment, distance 820 is about 30 centimeters. The distance between inner support arms 740 and support frame 720 is denoted 830. In one embodiment, distance 830 is between 60-120 centimeters, optionally 80-100 centimeters. These distances 830 short enough to allow support frame 720 to support inner support arms 740 and outer support arms 750 and long enough to allow space to work and walk through.

As illustrated in FIG. 7E, support structure further comprises a plurality of elongated strengthening arms 840. A first set of strengthening arms 840 extend from first inner support arm 740 to support frame 720 and a second set of strengthening arms 840 extend from second inner support arm 740 to support frame 720, thereby strengthening the connection between inner support arms 740 to support frame 720. In one embodiment, each set of strengthening arms 840 comprises a plurality of strengthening arms 840 in a ladder like structure and generally evenly spaced. In another embodiment, strengthening arms 840 is positioned within support structure 710, i.e. in the space between the pair of inner support arms 740, such that a plurality of support structures 710 can be positioned flush against each other as illustrated in FIG. 7F.

As illustrated in FIG. 7B, in a first stage of construction, where inner support arms 740 and strengthening arms 840 are not yet provided, a first strip 120 is secured to the bottom of each outer support arm 750. Particularly, a plurality of support extension members 850 are provided, each exhibiting a first end 852 and a second end 854 opposing first end 852. In one embodiment, each support extension member is a bar about 8 millimeters thick. A first support extension member 850 extends through a respective hole 140 of first strip 120 and is secured to first outer support arm 750 at first end 852 thereof. A second support extension member 850 extends through a respective hole 140 of first strip 120 and is secured to second outer support arm 750 at first end 852 thereof. In one embodiment, first end 852 is sharpened to allow support extension members 850 to be screwed into the respective outer support arms 750. In one embodiment, a plastic sheath (not shown) is arranged to cover each support extension member 850 to allow easier extraction of support extension members 850 from hardenable material, as will be described below. Additionally, in one embodiment, a plurality of free extension members 860 are provided, each exhibiting a first end 862 and a second end 864 opposing first end 862. In one embodiment, each free extension member 860 is a bar about 8 millimeters thick. First end 862 of each of a pair of free extension members 860 extend through a respective hole 140 of first strip 120. In one embodiment, a cap is screwed over first end 862 of each free extension member 860 so as to remain secured to first strip 120.

A first slab 110 is the positioned over the secured first strip 120, with first strip 120 disposed within slit 130 of first side 113 of first slab 110, as described above in relation to enclosure member 100 of FIGS. 2A-21. A second strip 120 is disposed within slit 130 of second side 114 of first slab 110 and a pair of support extension members 850 and a pair of free extension members 860 are inserted through respective holes 140 of second strip 120, as described above. Slabs 110 and strips 120 are interchangeably positioned over each other, with support extension members 850 and free extension members 860 inserted through respective holes 140, until the uppermost strip 120 is adjacent to extension arms 730, as illustrated in FIG. 7C.

As further illustrated in FIG. 7C, a panel 870 and a panel 880 are provided. Panel 870 exhibits an inner face 872 and an outer face 874 opposing inner face 872. Panel 880 exhibits an inner face 882 and an outer face 884 opposing inner face 882. In one non-limiting embodiment, panel 870 and panel 880 are each a RAPID composite wall panel commercially available from Green & Easy House Inc. of Rishon Le'tzion, Israel. Outer face 874 of panel 870 is positioned against slabs 110 with support extension members 850 and free extension members 860 extending therethrough such that panel 870 and slabs 110 for an enclosure member 890, as described above in relation to insulation layer 150. Particularly, inner face 874 of panel 870 faces support frame 720. Outer face 874 of panel 870 substantially covers all of the stacked slabs 110 and strips 120. Panel 880 is positioned between panel 870 and support frame 720 such that inner face 882 of panel 880 faces inner face 872 of panel 870 with support extension members 850 and free extension members 860 extending therethrough, thereby forming an enclosure member 900. In one embodiment, the size and shape of panels 870 and 880 are generally equal. A space 70 is thus defined between enclosure members 890 and 900, i.e. between inner face 872 of panel 870 and inner face 882 of panel 880.

As illustrated in FIG. 7D, first and second inner support arms 740 are positioned against outer face 884 of panel 880 with support extension members 850 extending through inner support arms 740. In one embodiment, a nut is screwed onto each support extension member 850 such that inner support arms 740 are secured to panel 880. In another embodiment, inner support arms 740 are each secured to the respective extension arm 730. Thus, enclosure member 890 is juxtaposed with inner support arms 740 and enclosure member 900 is juxtaposed with outer support arms 750. As illustrated in FIG. 7E, elongated strengthening arms 840 are secured to inner support arms 740 and support frame 720, as described above.

As illustrated in FIG. 7F, a plurality of support structures 710, with the respective slabs 110, strips 120, support extension members 850, free extension members 860, panel 870 and panel 880, are positioned adjacent to each other such that panels 870 form a single panel and panels 880 form a single panel with space 70 defined therebetween. As illustrated in FIG. 7G, hardenable material 80 is poured into space 70.

As illustrated in FIG. 7H, after hardenable material 80 is poured and the pressure applied to panels 870 and 880 is reduced, inner support arm 740 and elongated strengthening arms 840 are removed. Support extension members are then extracted from outer support arms 750 and removed from hardenable material 80. As illustrated in FIG. 7I, outer support arms 750 are removed. In one embodiment, outer support arms 750 are removed together with extension arms 730. As described above in relation to FIGS. 1-3, a wall comprised of hardenable material 80 is sandwiched between panel 880 the combination of panel 870 and slabs 110, with free extension members 860 securing slabs 110, via strips 120, to panel 870.

Advantageously, temporary hardenable material construction apparatus 700 allows to construct building walls without the use of cranes, or with limited use thereof, since the walls are constructed utilizing the support of support frames 720 which are inside the building. It is particularly noted that the features of temporary hardenable material construction apparatus 700 can be incorporated with the features of temporary hardenable material construction apparatuses 200 and 300, and the appropriate features of temporary hardenable material construction apparatuses 10, 400, 500 and 600, as would be clear to one skilled in the art at the time of the invention.

Although the above has been described wherein a plurality of free extension members 860 are provided to secure panels 870 and 880 to strips 120, this is not meant to be limiting in any way. In another embodiment (not shown), strips 120 are secured to a grid assembly, such as grid assembly 310 described above, optionally by metal wires bent through a pair of holes 140 and tied to the grid assembly after being inserted through panel 870. Similarly, panel 880 is secured to the grid assembly, optionally by bent metal wires being inserted therethrough at at least two points and tied to the grid assembly.

FIG. 8A illustrates a high level flow chart of a second hardenable material construction method. In stage 4000, an outer face of a first enclosure member is juxtaposed with a first outer support arm. The first outer support arm extends from a support frame. Optionally, the first outer support arm extends across the entirety of the outer face of the first enclosure member. Optionally, the first outer support arm is secured to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to the securement to the first extension arm. In stage 4010, a first end of at least one support extension member is secured to the first outer support arm of stage 4000.

In stage 4020, a first inner support arm is juxtaposed with an outer face of a second enclosure member. The first inner support arm extends from the support frame of stage 4000. Optionally, the first inner support arm extends across the entirety of the outer face of the second enclosure member. Optionally, the first inner support arm is secured to a first extension arm extending from the support frame, the extension of the first inner support arm from the support frame responsive to the securement to the first extension arm. Optionally, the distance between the support frame and the second enclosure member is 60-120 centimeters, further optionally 80-100 centimeters. In stage 4030, a second end of the at least one support extension member of stage 4010 is secured to the first inner support arm of stage 4020.

In stage 4040, subsequent to the securing of stages 4010 and 4030, hardenable material is placed into the space defined between an inner face of the first enclosure member of stage 4000 and the inner face of the first enclosure member of stage 4020. The secured at least one support extension member of stages 4010 and 4030 extends through the first and second enclosure member.

In optional stage 4050, prior to the placement of hardenable material of stage 4040, a second outer support arm and a second inner support arm are each secured to a second extension member which extends from the support frame of stage 4000. The at least one support extension member comprises a plurality of support extension members. A first end of a first support extension member is secured to the first outer support arm of stage 4000. A first end of a second support extension member is secured to the second outer support arm. A second end of the first support extension member is secured to the first inner support arm of stage 4020. A second end of the second support extension member is secured to the second inner support arm.

In optional stage 4060, prior to the placement of hardenable material of stage 4040, elongated strengthening arms are each secured between the first inner support arm of stage 4020 and the support frame of stage 4000.

In optional stage 4070, prior to the placement of hardenable material of stage 4040, a plurality of free extension member are extended through the first enclosure member of stage 4000 and the second enclosure member of stage 4020. The free extension members are not secured to either the first outer support arm of stage 4000 or the first inner support arm of stage 4020.

In optional stage 4080, an insulation layer is secured to an outer layer of the first enclosure member of stage 4000, with securing members each disposed on a respective free extension member of optional stage 4070. In optional stage 4090, prior to the placement of hardenable material of stage 4040, a grid assembly is disposed within the defined space of stage 4040. The grid assembly is further secured to a free extension member of optional stage 4070 so as to separate the grid assembly from the insulation layer of optional stage 4080 by at least a predetermined distance.

FIG. 8B illustrates a high level flow chart of optional stages of forming the first enclosure of stage 4000 of FIG. 8A. In stage 5000, a first side of each of a plurality of slabs is positioned to face a second side of another of the plurality of slabs, the second side of each of the plurality of slabs opposing the first side thereof. The first side and second side of each of the plurality of slabs exhibit a slit configured to receive a respective one of a plurality of strips. In stage 5010, a respective one of the plurality of strips of stage 5000 is disposed within the slit of the first side of each of the plurality of slabs of stage 5000 and the slit of the second side of the respective another slab.

In stage 5020, the at least one support extension member of stage 4010 is inserted through a respective one of a plurality of facade securing elements, the facade securing elements each secured to one of a plurality of facade members. Optionally, each facade member comprises a slab of stage 5000 and each facade securing element comprises a strip of stage 5010. Optionally, the extension of the at least one support extension member through the first enclosure member of stage 4040 is responsive to the insertion through the respective facade securing element.

In optional stage 5030, each of a plurality of L-shaped corner members, each exhibiting a first end and a second end perpendicular to the first end, is disposed within the slit of the first side of a first of the plurality of slabs of stage 5000 and within the slit of the first side of a second of the plurality of slabs.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein.

All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the patent specification, including definitions, will prevail. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

The terms “include”, “comprise” and “have” and their conjugates as used herein mean “including but not necessarily limited to”.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.

Claims

1. A temporary hardenable material construction apparatus comprising:

a support structure comprising a support frame, a first inner support arm extending from said support frame and a first outer support arm extending from said support frame;

at least one support extension member, said at least one support extension member exhibiting a first end and a second end opposing said first end;

a first enclosure member exhibiting an inner face and an outer face opposing said inner face; and

a second enclosure member exhibiting an inner face and an outer face opposing said inner face, said second enclosure member positioned in parallel with said first enclosure member such that a space is defined between said inner face of said first enclosure member and said inner face of said second enclosure member,

wherein said first outer support arm is juxtaposed with said outer face of said first enclosure member,

wherein said first inner support arm is juxtaposed with said outer face of said second enclosure member,

wherein said at least one support extension member extends through said first enclosure member and said second enclosure member such that said first end of said at least one support extension member extends past said outer face of said first enclosure member and said second end of said at least one support extension member extends past said outer face of said second enclosure member, and

wherein said first end of said at least one support extension member is secured to said first outer support arm and said second end of said at least one support extension member is secured to said first inner support arm.

2. The apparatus of claim 1, wherein said support structure further comprises a first extension arm extending from said support frame, said extension of said first outer support arm from said support frame responsive to said first outer support arm being secured to said first extension arm and said extension of said first inner support arm from said support frame responsive to said first inner support arm being secured to said first extension arm.

3. The apparatus of claim 2, wherein said support structure further comprises a second extension arm extending from said support frame, a second inner support arm secured to said second extension arm and a second outer support arm secured to said second extension arm, and

wherein said at least one support extension member comprises a plurality of support extension members, said first end of a first of said plurality of support extension members secured to said first outer support arm, said first end of a second of said plurality of support extension members secured to said second outer support arm, said second end of said first of said plurality of support extension members secured to said first inner support arm and said second end of said second of said plurality of support extension members secured to said second inner support arm.

4. The apparatus of claim 1, wherein said support structure further comprises a plurality of elongated strengthening arms, each exhibiting a first end and a second end opposing said first end, and

wherein said first end of each of said plurality of elongated strengthening arms is secured to said first inner support arm and said second end of each of said plurality of elongated strengthening arms is secured to said second inner support arm.

5. The apparatus of claim 1, wherein the distance between said support frame and said second enclosure member is 60-120 centimeters.

6. (canceled)

7. The apparatus of claim 1, further comprising a plurality of free extension members, each of said plurality of free extension members exhibiting a first end and a second end opposing said first end,

wherein each of said plurality of free extension members extends through said first enclosure member and said second enclosure member, and

wherein said first end of each of said plurality of free extension members is not secured to said first outer support arm and said second end of each of said plurality of free extension members is not secured to said first inner support arm.

8. The apparatus of claim 1, wherein said first inner support arm extends across the entirety of said outer face of said second enclosure member, and

wherein said first outer support arm extends across the entirety of said outer face of said first enclosure member.

9-14. (canceled)

15. A structure comprising:

a plurality of extension members, each of said plurality of extension members exhibiting a first end and a second end opposing said first end;

a first enclosure member exhibiting an inner face and an outer face opposing said inner face; and

a second enclosure member exhibiting an inner face and an outer face opposing said inner face, said second enclosure member positioned in parallel with said first enclosure member such that a space is defined between said inner face of said first enclosure member and said inner face of said second enclosure member, said space filled with a wall layer of hardenable material;

wherein each of said plurality of extension members extends through said first enclosure member and said second enclosure member, and

wherein said first enclosure member comprises: a plurality of facade members; and a plurality of facade securing elements, each of said plurality of facade securing elements secured to a perimeter of a respective one of said plurality of facade members,

wherein each of said plurality of extension members extends through a respective one of said plurality of facade securing elements.

16. The structure of claim 15, wherein each of said plurality of facade securing elements comprises a strip,

wherein each of said plurality of facade members comprises a slab, each of said plurality of slabs exhibiting a first face, a second face opposing said first face, a first side extending from said first face to said second face and a second side opposing said first side, each of said first side and said second side exhibiting a slit therealong, said slit configured to receive a respective one of said plurality of strips, and

wherein said first side of each of said plurality of slabs faces said second side of another of said plurality of slabs, a respective one of said plurality of strips disposed within said slit of said first side of said respective slab and within said slit of said second side of said another respective slab, each of said plurality of extension members extending through a respective one of said plurality of strips.

17. The structure of claim 16, further comprising a plurality of L-shaped corner members, each of said L-shaped corner members exhibiting a first end and a second end perpendicular to said first end, said slit of each of said plurality of slabs further configured to receive one of a first end and a second end of a respective one of said plurality of L-shaped corner members, wherein said at least one first enclosure member comprises a pair of first enclosure members positioned perpendicular to each other, said first end of each of said plurality of L-shaped corner members disposed within said slit of said first side of a respective one of said plurality of slabs of a first of said pair of first enclosure members and said second end of each of said plurality of L-shaped corner members disposed within said slit of said first side of a respective one of said plurality of slabs of a second of said pair of first enclosure members.

18. The structure of claim 15, wherein said first enclosure member comprises:

an outer layer exhibiting an inner face and an outer face opposing said inner face, said outer face of said first enclosure member comprising said outer face of said outer layer, said outer layer comprising said plurality of facade members and said plurality of facade securing elements; and

an insulation layer exhibiting an inner face and an outer face opposing said inner face, said inner face of said insulation layer facing said inner face of said second enclosure member, said outer face of said insulation layer facing said inner face of said outer layer.

19. The structure of claim 18, wherein said outer face of said insulation layer is in direct contact with said inner face of said outer layer.

20. The structure of claim 18, further comprising:

a grid assembly disposed within said hardenable material;

a plurality of securing members, each of said plurality of securing members disposed on a respective one of said plurality of extension members and juxtaposed with said insulation layer to secure said insulation layer to said outer layer; and

wherein said grid assembly is secured to one of said plurality of extension members so as to separate said grid assembly from said insulation layer by at least a predetermined distance.

21. The structure of claim 15, further comprising:

a ceiling panel positioned over said second enclosure member; and

a ceiling layer of hardenable material disposed on said ceiling panel, said insulation layer of said first enclosure member rising above said ceiling layer of hardenable material.

22. A hardenable material construction method, the method comprising:

juxtaposing an outer face of a first enclosure member to a first outer support arm, the first outer support arm extending from a support frame;

securing a first end of at least one support extension member to the first outer support arm;

juxtaposing a first inner support arm to an outer face of a second enclosure member, the first inner support arm extending from a support frame;

securing a second end of the at least one support extension member to the first inner support arm; and

subsequent to said securing the at least one support extension member to the first inner support arm, placing hardenable material into the space defined between an inner face of the first enclosure member and an inner face of the second enclosure member, the inner face of the first enclosure member opposing the outer face of the first enclosure member and the inner face of the second enclosure member opposing the outer face of the second enclosure member,

wherein said secured at least one support extension member extends through the first enclosure member and the second enclosure member.

23. The method of claim 22, further comprising, prior to said placing:

securing the first outer support arm to a first extension arm extending from the support frame, the extension of the first outer support arm from the support frame responsive to said securing; and

securing the first inner support arm to the first extension arm, the extension of the first inner support arm from the support frame responsive to said securing.

24. The method of claim 23, wherein the at least one support extension member comprises a plurality of support extension members, the method further comprising, prior to said placing:

securing a second outer support arm to a second extension arm extending from the support frame; and

securing a second inner support arm to the second extension arm,

wherein the first end of a first of the plurality of support extension members secured to the first outer support arm, the first end of a second of the plurality of support extension members secured to the second outer support arm, the second end of the first of the plurality of support extension members secured to the first inner support arm and the second end of the second of said plurality of support extension members secured to the second inner support arm.

25. The method of claim 22, further comprising, prior to said placing:

securing a first end of each of a plurality of elongated strengthening arms to the first inner support arm; and

securing a second end of each of the plurality of elongated strengthening arms to the support frame.

26-27. (canceled)

28. The method of claim 22, further comprising, prior to said placing, extending a plurality of free extension members through the first enclosure member and the second enclosure member,

wherein said extended free extension members are not secured to said first inner support arm or to said first outer support arm.

29. The method of claim 22, wherein the first inner support arm extends across the entirety of the outer face of the second enclosure member, and

wherein the first outer support arm extends across the entirety of the outer face of the first enclosure member.

30-35. (canceled)