SYSTEM FOR APPLYING CEMENTITIOUS MATERIAL

Abstract

Systems for applying cementitious material, processes of producing construction outputs, and construction outputs are disclosed. Embodiments of the systems include an outlet for introducing the cementitious material to a region arranged and disposed to receive the cementitious material, a movable flow pathway for transporting the cementitious material to the outlet, and a suspension element suspending the outlet and at least a portion of the movable flow pathway above the region. The suspension element extends from an arrangement outside the region. The processes use the systems. The construction outputs are produced by the systems.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims benefit of U.S. provisional Application no. 63/796,712 entitled “SYSTEM FOR APPLYING CEMENTITIOUS MATERIAL,” filed Apr. 29, 2025, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to construction. More particularly, the present invention is directed to systems for applying cementitious material, processes of producing construction outputs, and such construction outputs.

BACKGROUND OF THE INVENTION

Construction can be physically demanding. With workforces aging and many individuals not being interested in physically demanding work, alleviating the physically demanding aspects of construction is important.

Pouring concrete is an example of such a physically demanding task. In bridge construction, pouring concrete can involve long and heavy rigid pipes and flexible hoses that extend along a bridge deck 100 as shown in FIG. 1. Some configurations include using wood, tires, cranes, trucks, and large crews to manage the assembly for the pouring. Moving them can be difficult, especially while navigating rebar, studs, deck pans, and other items on a bridge construction site. Without concrete in the pipes and hoses, the pipes and hoses can weigh 100 pounds. With concrete in them, they can weigh 400 pounds.

To alleviate some of the difficulty, the four-wheeled device 200 in FIG. 2 has been used. The device is limited in the weight it can manage (maximum of 118 pounds), substantially limiting the ability to alleviate the physically demanding aspects of pouring concrete. In addition, the device traverses across a surface, such as, on rebar, studs, deck pans, and/or other surfaces to receive the concrete. Such traversing can cause movement (especially of the rebar and the deck pans), can get stuck, can disrupt the overall pouring process, and otherwise can cause substantial challenges for the crew operating in conjunction with the device. Other devices and techniques have not sufficiently addressed the physically demanding work in a manner that allows smaller crews to operate and/or allows maximum flexibility in operational control.

Systems, processes, and outputs that do not suffer from such drawbacks would be desirable in the art.

BRIEF DESCRIPTION OF THE INVENTION

In an embodiment, a system for applying a cementitious material to produce a bridge includes an outlet for introducing the cementitious material to a region defined by bridge deck pans arranged and disposed to receive the cementitious material, a movable flow pathway for transporting the cementitious material to the outlet, and a suspension element suspending the outlet and at least a portion of the movable flow pathway above the region. The suspension element extends from an arrangement outside the region.

In another embodiment, a system for applying concrete to produce a construction output includes an outlet for introducing the concrete to a region arranged and disposed to receive the concrete, a movable flow pathway for transporting the concrete to the outlet, and a suspension element suspending the outlet and at least a portion of the movable flow pathway above the region. The suspension element extends from an arrangement outside the region.

Further embodiments, in addition to those expressly recited in the claims and throughout the application, include any suitable combinations between claims 1-3, claims 1-4, claims 1-5, claims 1-6, claims 1-7, claims 1-8, claims 1-9, claims 1-10, claims 1-11, claims 1-12, claims 1-13, claims 1-14, claims 1-15, claims 1-16, claims 1-17, claims 1-18, and claims 1-19, with any of the dependent claims omitted or included in such embodiments.

Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a prior art system and technique of using slick lines to pour concrete on a bridge.

FIG. 2 shows a prior art system for introducing concrete to a sub-surface.

FIG. 3 shows an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 4 shows an embodiment of a system for applying a cementitious material, while the cementitious material is being applied, according to the disclosure.

FIG. 5 shows an embodiment of a suspension element having a handle for use with an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 6 shows an embodiment of a suspension element having multiple brackets for use with an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 7 shows a clamp for securing segments of a movable flow pathway of an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 8 shows exemplary flexible hoses for a movable flow pathway of an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 9 shows exemplary rigid pipes for a movable flow pathway of an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 10 shows an exemplary sled for moving portions of a movable flow pathway of an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 11 shows an embodiment of a suspension element having multiple racks for use with an embodiment of a system for applying a cementitious material, according to the disclosure.

FIG. 12 shows an embodiment of a suspension element having multiple platforms for use with an embodiment of a system for applying a cementitious material, according to the disclosure.

Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided are systems, processes, and outputs, according to embodiments of the disclosure. Embodiments of the present disclosure, for example, in comparison to concepts failing to include one or more of the features disclosed herein, permit safer construction (for example, of bridges), permit safer manipulation of concrete, permit more precise deployment of concrete, permit more efficient operations, permit a broader pool of individuals to be involved in the construction industry, or permit a combination thereof.

Referring to FIGS. 3-4, in one embodiment, a system 101 for applying a cementitious material 401 (FIG. 4) includes an outlet 102 for introducing the cementitious material 401 to a region 104. The region 104 is defined by any suitable borders, designs, plans, and/or barriers for identifying a target location of the cementitious material 401. In one embodiment, the region 104 is defined by one or more deck pans 106, a lattice of rebar 109, a sub-surface 135, locations supported by beams 133, locations supported by pillars 131, or a combination thereof. In another embodiment, the region 104 is defined by previously-poured cementitious material, filler, tie-layers, other foundational materials, or a combination thereof.

The system 101 further includes a movable flow pathway 108 for transporting the cementitious material 401 to the outlet 102, and a suspension element 110 suspending the outlet 102 and at least a portion of the movable flow pathway 108 above the region 104. The suspension element 110 extends from an arrangement outside the region 104. As used herein, the term “suspension” and grammatic variations thereof are used for defining a characteristic of relative positioning in the direction of or generally in the direction of gravity. Other terms of position are intended to similarly relate to gravity, for example, with down and below being the direction of or generally the direction of gravity, up and above being the opposite direction, and lateral, sideways, and transverse terms being perpendicular or generally perpendicular to gravity.

The outlet 102 is any suitable mechanism for controlling or measuring flow within the moveable path 108 and/or fostering specific types of flow (for example, flow that is more laminar in nature or flow that is more turbulent in nature). In one embodiment, the outlet 102 is or includes a flow meter (for example, measuring flow rate, acoustics, vibration, motion, or combinations thereof). In one embodiment, the outlet 102 is or includes a nozzle (for example, a converging nozzle, a cylindrical nozzle, a swirling nozzle, or a combination thereof). In one embodiment, the outlet 102 is or includes a valve (for example, lever, a shut-off valve, a restricting valve activated based upon a signal from the source 112, or a combination thereof).

Use of the controlling and/or the measuring of the flow within the movable path 108 of the cementitious material 401 allows capturing of data and monitoring of the cementitious material 401. For example, in one embodiment, the capturing of the data allows for a more precise thickness of the cementitious material 401 to be applied. The more precise thickness allows less waste (for example, from adding too much of the cementitious material 401), allows easier compliance (for example, making sure to avoid being too thin with the cementitious material 401), allows better monitoring of costs (for example, being able to pay labor for a specific amount/weight of the cementitious material 401 used instead of merely ordered/delivered), allows capturing of other pecuniary aspects tied to the amount of the cementitious material 401 used (for example, by being captured in carbon credits and/or carbon-focused tax advantages), or a combination thereof. In a further embodiment, sensors for curing or otherwise monitoring of concrete are embedded, for example, allowing for such data to be captured over a period of time.

The movable flow pathway 108 transports the cementitious material 401 from a source 112, such as a concrete truck, a hopper, a plant, or a combination thereof. The source 112 is positioned on a previously-cured section, on nearby ground 125, in nearby water 111, on a nearby road 123, outside the footprint of the construction output, within the footprint of the construction output, or in any suitable location.

The movable flow pathway 108 has a length extending from the outlet 102 to the source 112, for example, being at least 25 feet, at least 50 feet, at least 75 feet, at least 100 feet, at least 200 feet, between 25 feet and 250 feet, between 50 feet and 250 feet, between 75 feet and 250 feet, between 100 feet and 250 feet, between 200 feet and 250 feet, between 25 feet and 200 feet, between 50 feet and 200 feet, between 75 feet and 200 feet, between 100 feet and 200 feet, between 25 feet and 100 feet, between 50 feet and 100 feet, between 75 feet and 100 feet, between 25 feet and 75 feet, between 50 feet and 75 feet, between 25 feet and 50 feet, or any suitable combination, sub-combination, range, or sub-range therein.

The movable flow pathway 108 is or includes any features enabling it to be used for the transporting of the cementitious material 401. In one embodiment, the movable flow pathway 108 is or includes a flexible hose 801 (see FIG. 8). In one embodiment, the movable flow pathway 108 is or includes a rigid pipe 901 (see FIG. 9). In one embodiment, the movable flow pathway 108 includes clamps 701 for securing segments of the movable flow pathway 108, such as the flexible hose(s) 801 and/or the rigid pipe(s) 901.

The movable flow pathway 108 is configured to move between cycles of the cementitious material 401 or while the cementitious material 401 is within the movable flow pathway 108. In embodiments with the cementitious material 401 within the movable flow pathway 108, the system 101 is able to support a predetermined load rating. The weight in the movable flow pathway 108 and/or the predetermined load rating are at least 120 pounds, at least 200 pounds, at least 300 pounds, between 120 pounds and 500 pounds, between 120 pounds and 300 pounds, between 120 pounds and 200 pounds, between 200 pounds and 500 pounds, between 200 pounds and 300 pounds, between 300 pounds and 500 pounds, or any suitable combination, sub-combination, range, or sub-range therein.

In one embodiment, the cementitious material 401 is or includes concrete. In further embodiments, the cementitious material 401 includes pulverized fuel ash (PFA), ground granulated blast-furnace slag (GGBS), silica fume, limestone fines, recycling of materials, ferrock, cements based on geopolymers, biocement, or a combination thereof.

The system 101 is capable of producing any construction output or portions thereof having the cementitious material 401, whether cast in place or pre-cast. Portions of the construction output include, but are not limited to, bridge decks, walkways, surfaces, floors, walls, ceilings, stairs, sub-structures, foundations, footers, and combinations thereof. In one embodiment, the construction output is a bridge or bridge deck. Other suitable construction outputs include structures such as residential structures (for example, houses, townhouses, apartment buildings, dormitories, and/or other similar structures), commercial structures (for example, malls, restaurants, grocery stores, hotels, parking structures, and/or stadiums), institutional structures (for example, libraries, court houses, government facilities, schools, museums, hospitals, military buildings, fire stations, police stations, and/or prisons), industrial structures (for example, warehouse and distribution centers, manufacturing facilities, power plants, water towers, wind farms, solar arrays, data centers, chemical processing facilities, and/or mining facilities), civil structures (for example, bridge decks, elevated superstructures, rail systems, roads, runways, tunnels, marine piers, and/or ramps), and/or any other suitable structures, groupings of structures, or construction projects.

Referring to FIG. 4, upon the cementitious material 401 being introduced to the region 104, curing is able to begin. Any suitable method of curing is able to be used, for example, water curing, wet covering, formwork curing, membrane curing, sheet curing, curing by absorbing heat, hot mixing, electrical curing, infra-red curing, natural curing, or a combination thereof. In further embodiments, portions of the curing are aided through the use of the system 101, for example, by positioning and re-positioning covers (for example, burlap covers, polymeric sheets, and/or wood), energy/heat source (for example, direct from a source or indirect, such as, from exhaust from a concrete truck, generator, or vehicle), curing aids/materials, or combinations thereof.

Referring again to FIGS. 3-4, in one embodiment, the suspension element 110 extends from a truss 105 of a gantry assembly 103 configured for traveling along a path 121, such as a screed rail or edgeform for a partially-constructed bridge 127. The gantry assembly 103 is supported by support legs 107. In a further embodiment, the gantry assembly 103 includes features, structures, and capabilities described in U.S. Pat. No. 10,061,323, entitled “Autonomous apparatus and system for repetitive tasks in construction project” and U.S. Pat. No. 10,597,264, entitled “Semi-autonomous system for carrying and placing elongate objects,” which are each incorporated by reference in their entirety. In other embodiments, the gantry assembly 103 is positioned on wheels.

FIGS. 5-6 and 10-12 show embodiments of the suspension element 110. The suspension element 110 is manually adjustable, electronically adjustable, autonomously adjustable, semi-autonomously adjustable, or a combination thereof. The adjusting allows the outlet 102 to position the cementitious material 401 throughout the region 104.

Referring to FIG. 5, in one embodiment, the suspension element 110 includes a manual rotation handle 501, allowing rotational adjustment of the outlet 102 and/or the movable flow pathway 108 when positioned within the suspension element 110. The suspension element 110 allows removal of the movable flow pathway 108, for example, by having a support bracket 503 connected to an enclosure brace 505 by a latch 507.

Referring to FIG. 6, in one embodiment, the suspension element 110 includes a plurality of the support brackets 503, allowing a transverse portion (not shown) of the movable flow pathway 108 to be supported, allowing a plurality of the movable flow pathways 108 to be supported, allowing more flexible operation of the system 101, or a combination thereof.

Referring to FIG. 10, in one embodiment, the suspension element 110 is or includes a sled 116 capable of being reversibly attached and removed from the system 101, thereby allowing a further degree of flexibility in operation. In a further embodiment, the suspension element 110 supporting the sled includes chains 114, links, cables, members, carabiners, winches, bolts, and/or other mechanisms for removably securing and allowing manipulation of the sled 116. The sled 116 is able to be releasably secured to any suitable portion of the system 101, thereby allowing operators to have flexibility of use during operation.

Referring to FIG. 11, in one embodiment, the suspension element 110 is or includes a set of support members 118 extending from the truss 105. The support members 118 allow for variation of height of the movable flow pathway 108 and/or the outlet 102, which may assist in flow of the cementitious material 401. Additionally or alternatively, the support members 118 allow for unused segments of the movable flow pathway 108 to be reversibly stored and deployed, for example, segments of the flexible hose(s) 801 and/or segments of the rigid pipe(s) 901.

Similar to the embodiment of FIG. 11, FIG. 12 shows an embodiment where the suspension element 110 is or includes a set of support members 118. The support members 118 of FIG. 12, however, extend from the support leg 107 of the system proximal to the path 121/edgeform of the partially-constructed bridge 127. The positioning of the support members 118 in FIG. 12 allows greater weight due to the proximity to the support leg 107.

According to an exemplary process, the system 101 moves along the path 121 while supporting the movable flow pathway 102. The moving is slewing, rotational motion, and/or linear at a rate of between 0 and 1.4 meters per second, between 0 and 2 meters per second, between 0 and 3 meters per second, between 0 and 4 meters per second, between 0 and 5 meters per second, between 1 and 2 meters per second, between 1 and 3 meters per second, between 1 and 4 meters per second, between 1 and 5 meters per second, between 1.4 and 2 meters per second, between 1.4 and 3 meters per second, between 1.4 and 4 meters per second, between 1.4 and 5 meters per second, between 1 and 2 meters per second, between 1 and 3 meters per second, between 1 and 4 meters per second, between 1 and 5 meters per second, or any suitable combination, sub-combination, range, or sub-range therein.

In alternative embodiments, modifications to the system 101 are made to adapt for entirely different applications from deploying of the cementitious material 401, for example, cleaning, carrying, preparing, hydro-demolotion, or otherwise managing the flow, in either direction (e.g., as vacuumed or blown), of a fluid (liquid, gas, slurry, etc.) and/or debris or other substances within the fluid. In such alternative embodiments or combinations with other disclosed embodiments, the source 112 is capable of being configured for water, waste, refuse, recyclable materials, chemicals, polymers, plastics, foam, solvents, cellulosic materials (for example, pulp and/or paper), cool air, hot air, oil, natural gas, gasoline, road treatment materials, or combinations thereof. Suitable devices for such modifications include vacuums, blowers, pressure-washers,

In yet other modifications, the system 101 is adapted to allow electrical, optical, and/or communication transmissions being in lines suspended from the system 101 and/or enclosed within the rigid pipes 901 and/or the flexible hoses 801. Suitable lines include cords, wires, cables, fibers, conductors, rails, and/or other similar lines. Being suspended and/or enclosed enhance accessibility (for example, by being in places not previously available), protects the lines (for example, by not being subjected to environmental or faulting materials onsite), prevents impact to onsite materials (for example, by not contacting materials that would be harmed by the transmissions), and/or enhances safety (for example, by preventing electrocution)

In one embodiment, the system 101 includes features to allow the process to be computer-implemented. This means the process is implemented in digital electronic circuitry or in computer software, firmware, or hardware, including the structures disclosed in this specification or in combinations of one or more of them.

In one embodiment, the process is implemented as operations performed by a data processing apparatus on data stored on one or more computer-readable storage devices or received from other sources.

In one embodiment, the data processing apparatus, computer, or computing device encompasses apparatus, devices, and machines for processing data, including, by way of example, a programmable processor, a computer, a system on a chip or multiple ones, or combinations, of the foregoing.

In one embodiment, the system 101 includes special purpose logic circuitry, for example, a central processing unit (CPU), a parallel graphics processing unit (GPU), a field programmable gate array (FPGA), an application-specific integrated circuit (ASIC), language processing unit (LPU), a neural processing unit (NPU), Tensor Processing Unit (TPU), a neural network (for example, a Deep Neural Network (DNN) or Convolutional Neural Network (CNN)), or a combination thereof

In one embodiment, the system 101 includes code that creates an execution environment for the computer program in question, for example, code that constitutes processor firmware, a protocol stack, a database management system, an operating system (for example, an operating system or a combination of operating systems), a cross-platform runtime environment, a virtual machine, or a combination of one or more of them.

In one embodiment, the system 101 and execution environment realize various different computing model infrastructures, such as web services, distributed computing and grid computing infrastructures.

As used herein, a “computer program” refers to an executable program of instructions able to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network. Generally, a computer also includes, or is operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data. A computer, or node, is capable of being embedded in another device, for example, a mobile device, a personal digital assistant (PDA), a game console, a Global Positioning System (GPS) receiver, or a portable storage device. Devices suitable for storing computer program instructions and data include non-volatile memory, media and memory devices, including, by way of example, semiconductor memory devices, magnetic disks, and magneto-optical disks. The processor and the memory are capable of being supplemented by, or incorporated in, special-purpose logic circuitry. Additionally, processors for execution of a computer program include, by way of example, both general-purpose and special-purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor receives instructions and data from a read-only memory or a random-access memory or both. The essential elements of a computer are a processor for performing actions in accordance with instructions and one or more memory devices for storing instructions and data.

While the invention has been described with reference to one or more embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. In addition, all numerical values identified in the detailed description shall be interpreted as though the precise and approximate values are both expressly identified.

Claims

1. A system for applying a cementitious material to produce a bridge, the system comprising:

an outlet for introducing the cementitious material to a region defined by bridge deck pans arranged and disposed to receive the cementitious material;

a movable flow pathway for transporting the cementitious material to the outlet; and

a suspension element suspending the outlet and at least a portion of the movable flow pathway above the region;

wherein the suspension element extends from an arrangement outside the region.

2. The system of claim 1, wherein the arrangement is a gantry assembly.

3. The system of claim 1, wherein the cementitious material is concrete.

4. The system of claim 1, wherein the movable flow pathway is fluidly connected to a cement container positioned at least 100 feet from the outlet.

5. The system of claim 1, wherein the movable flow pathway is fluidly connected to a cement container positioned within a concrete truck.

6. The system of claim 1, wherein the movable flow pathway is fluidly connected to a cement container positioned within a concrete truck, the concrete truck positioned on a previously-cured section of the bridge.

7. The system of claim 1, wherein the movable flow pathway is fluidly connected to a cement container positioned within a concrete truck, the concrete truck positioned beyond a footprint of the bridge.

8. The system of claim 1, wherein the portion of the movable flow pathway includes a flexible hose.

9. The system of claim 1, wherein the portion of the movable flow pathway includes a rigid pipe.

10. The system of claim 1, wherein the portion of the movable flow pathway includes the cementitious material.

11. The system of claim 1, wherein the portion of the movable flow pathway has a mass of greater than 120 pounds without the cementitious material.

12. The system of claim 1, wherein the portion of the movable flow pathway includes the cementitious material and has a mass of greater than 300 pounds.

13. The system of claim 1, wherein the suspension element extends from a truss.

14. The system of claim 1, wherein the suspension element is manually adjustable, allowing the outlet to be positioned throughout the region.

15. The system of claim 1, wherein the suspension element is electronically adjustable, allowing the outlet to be positioned throughout the region.

16. The system of claim 1, wherein the suspension element is autonomously adjustable, allowing the outlet to be positioned throughout the region.

17. The system of claim 1, wherein the suspension element includes a handle for manual rotational manipulation of the suspension element and a bracket for receiving a portion of the movable flow pathway.

18. The bridge of claim 1, wherein the bridge includes the cementitious material being cured.

19. A process of producing the bridge of claim 1, wherein the process includes the introducing of the cementitious material to the region.

20. A system for applying concrete to produce a construction output, comprising:

an outlet for introducing the concrete to a region arranged and disposed to receive the concrete;

a movable flow pathway for transporting the concrete to the outlet; and

a suspension element suspending the outlet and at least a portion of the movable flow pathway above the region;

wherein the suspension element extends from an arrangement outside the region.