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US20090049762A1 - Building Core Slipform - Google Patents

Building Core Slipform Download PDF

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Publication number
US20090049762A1
US20090049762A1 US11/843,464 US84346407A US2009049762A1 US 20090049762 A1 US20090049762 A1 US 20090049762A1 US 84346407 A US84346407 A US 84346407A US 2009049762 A1 US2009049762 A1 US 2009049762A1
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United States
Prior art keywords
extendable
mechanisms
building core
frame
elevation
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US11/843,464
Inventor
David E. Termohlen
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THORNTON-TERMOHLEN GROUP Corp
Thornton Termohlen Group Corp
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Thornton Termohlen Group Corp
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Publication date
Application filed by Thornton Termohlen Group Corp filed Critical Thornton Termohlen Group Corp
Priority to US11/843,464 priority Critical patent/US20090049762A1/en
Assigned to THORNTON-TERMOHLEN GROUP CORPORATION reassignment THORNTON-TERMOHLEN GROUP CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TERMOHLEN, DAVID E.
Publication of US20090049762A1 publication Critical patent/US20090049762A1/en
Abandoned legal-status Critical Current

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/06Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
    • E04G11/20Movable forms; Movable forms for moulding cylindrical, conical or hyperbolical structures; Templates serving as forms for positioning blocks or the like
    • E04G11/22Sliding forms raised continuously or step-by-step and being in contact with the poured concrete during raising and which are not anchored in the hardened concrete; Arrangements of lifting means therefor

Definitions

  • This invention relates generally to building construction. More specifically the invention relates to systems and methods of creating vertical core structures about which buildings may be built.
  • Typical slip forming systems known in the art are custom manufactured on site by carpenters per engineering plans for different size building cores. Even after constructed, more materials, besides those actually used to construct the building core, are necessary for the slip form to advance upward to create the building core.
  • a system for slip forming a building core may include a form and a plurality of extendable mechanisms.
  • the form may include an inner frame and an outer frame.
  • the outer frame and the inner frame may at least partially define a space between the inner frame and the outer frame.
  • the form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form at least a portion of the building core.
  • Each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection.
  • the first end may be coupled with the form
  • the second end may be configured to be supported with a wall of the building core
  • the extendable midsection may be configured to change the distance between the first end and the second end such that the form may be moved from a first elevation to a second elevation.
  • a method for creating a structure may include providing a form, where the form includes an inner frame and an outer frame which may at least partially define a space between the inner frame and the outer frame.
  • the method may also include depositing a hardenable substance in the space, where the hardenable substance may form at least a portion of the structure.
  • the method may further include providing a plurality of extendable mechanisms, where the plurality of extendable mechanisms may be coupled with the form.
  • the method may additionally include supporting the plurality of extendable mechanisms from one or more walls of the structure.
  • the method may furthermore include extending the extendable mechanism such that the form may be moved from a first elevation to a second elevation.
  • a system for creating a structure may include a first means, a second means, and a third means.
  • the first means may be for at least partially defining a space, where the space may be configured to accept a hardenable substance.
  • the hardenable substance may form at least a portion of the structure.
  • the second means may be for providing support from a plurality of locations on at least one wall of the structure.
  • the third means may be for moving the first means away from the second means such that the first means may be moved from a first elevation to a second elevation, where the third means may be coupled with the first means and supported by the second means.
  • FIG. 1 is an axonometric view of a concrete pad prepared prior to slip forming
  • FIG. 1A is a side sectional view of a support bearing cavity on the form of FIG. 1 ;
  • FIG. 2 is an axonometric exploded view of a slip forming system
  • FIG. 3 is an axonometric assembled view of the slip forming system in FIG. 2 on the concrete pad from FIG. 1 ;
  • FIG. 4 is a plan view of FIG. 3 ;
  • FIG. 5 is an axonometric view of the slip forming system from FIG. 3 , after it has begun to form the lower part of the building core;
  • FIG. 6 is an axonometric view of the slip forming system from FIG. 5 , after it has formed more of the building core;
  • FIG. 7 is an axonometric view of the complete building core from FIG. 6 .
  • a system for slip forming a building core may include a form and a plurality of extendable mechanisms.
  • the form may provide a space for accepting a hardenable substance, for example, concrete, and the plurality of extendable mechanisms may move the form to higher elevations once lower elevations of the building core is formed.
  • a hardenable substance for example, concrete
  • the systems disclosed herein may be used to manufacture any number of different structures, especially vertical structures with an at least semi-consistent horizontal cross section.
  • floors of a building surrounding the building cores produced by the systems and methods of the invention may be supported at least in part by the building core.
  • the forms discussed herein may include an inner frame and an outer frame.
  • the outer frame and the inner frame may at least partially define a space between the inner frame and the outer frame.
  • the form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form at least a portion of the building core.
  • the inner frame and/or the outer frame of the form may be constructed from a variety of materials, including, but not limited to, metals (i.e. steel), polymers (i.e. plastics), ceramics, composites, and/or cellular materials (i.e. wood).
  • metals i.e. steel
  • polymers i.e. plastics
  • ceramics i.e. composites
  • cellular materials i.e. wood
  • fiberglass tubing and sheeting may be molded, fused, or otherwise joined together to create the inner frame and/or the outer frame.
  • metallic, possibly steel and/or aluminum, reinforcement members may be fiberglassed into the inner frame and/or the outer frame.
  • various external features of the inner frame and/or the outer frame may also include metallic elements.
  • the inner frame and the outer frame may each, or combined, be a singular piece, or include multiple sub-parts.
  • the inner frame and/or the outer frame may include a plurality of sub-frame components.
  • the sub-frame components may be configured to be reversibly assembled and disassembled, thereby easing transportation and assembly at a job site.
  • either one or both of the inner form and the outer form may include a plurality of end sub-frame components, a plurality of side sub-frame components, and a plurality of corner sub-frame components.
  • the inner frame and/or the outer frame may have pre-drilled or otherwise defined apertures for coupling finishing sheeting with the walls of the space where the hardenable substance is to be deposited.
  • plywood and/or other composite/cellular sheets may be coupled with the walls of the space where the hardenable substance is to be deposited via screws and/or other fasteners via pre-drilled apertures passing through the walls of the inner form and the outer form.
  • the extendable mechanisms may be coupled with the corner sub-frame components of either one or both of the inner frame and the outer frame.
  • the end sub-frame components and the side end-frame components may be substantially two sided, flat, and light-weight.
  • the corner end-frame components may carry the more substantial weight of the extendable mechanisms.
  • standardized corner sub-frame components may be used with differently dimensioned end sub-frame components and side sub-frame components to allow for the creation of different size building cores merely by altering which side sub-frame components and end sub-frame components are used with the corner sub-frame components having the extendable mechanisms.
  • joint members may be inserted into cavities in each adjacent sub-frame component to at least assist in joining such adjacent sub-frame components.
  • Different adjacent sub-frame components may have differing number of cavities for differing number of joint members to be used to connect those adjacent sub-frame components.
  • flanges on the exterior of the outer frame sub-frame components, as well as flanges on the interior of the inner frame sub-frame components may allow for fasteners or other mechanisms to couple adjacent sub-frame components. Any other mechanism known in the art or otherwise may also be used to couple adjacent sub-frame components.
  • At least one bridge member may be coupled with the inner frame and the outer frame such that the inner frame remains substantially stationary relative to the outer frame.
  • Bridge members may be reversibly coupled so that they may be attached/detached with the form as needed during assembly, use, or disassembly.
  • the bridge member or members may be configured to allow a reinforcement member to be deposited beneath the at least one bridge member in the space. Reinforcement members may, merely by way of example, include rebar, rebar cages, or wire mesh.
  • each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection.
  • the first end may be coupled with the form
  • the second end may be configured to be supported with a wall of the building core
  • the extendable midsection may be configured to change the distance between the first end and the second end such that the form may be moved from a first elevation to a second elevation.
  • the second end of the extendable mechanisms may be pushed away or pulled toward the first end, which may be fixedly coupled with the form.
  • one or more of the extendable mechanisms may be hydraulic cylinders. In other embodiments, one or more of the extendable mechanisms may be pneumatic cylinders and/or mechanical jacking systems (i.e. screw jacks or ratcheting jacks). In some embodiments, the power source for the extendable mechanisms may be provided at ground level, or may be self contained and coupled with the form, for example, on a operator working level coupled with the top, middle and/or bottom of the form.
  • the plurality of extendable mechanisms may include two sets of extendable mechanisms.
  • a first set of extendable mechanisms may be coupled with the inner frame of the form, and a second set of extendable mechanisms may be coupled with the outer frame of the form.
  • the two sets of extendable mechanisms may be aligned such that each extendable mechanism in the first set is linearly aligned with an extendable mechanism in the second set.
  • the pushing faces of the second end of the extendable mechanisms may be contoured to match a temporary support member that will be used to provide a jacking point on the wall of the building core.
  • the pushing faces may be flat and/or have a depressed or protruded feature.
  • the temporary support members may be flat and/or have a protruded or depressed feature, respectively, to match the pushing faces.
  • the pushing faces of the second end of the extendable mechanisms may define a cavity having a circular cross section.
  • the temporary support members may have a circular cross section. In some embodiments, combinations of different pushing faces on different extendable mechanisms may be employed.
  • initial push-off from ground level may include providing a concrete pad from which the building core will be supported.
  • the concrete pad may also have foundational elements such as concrete caissons.
  • cavities may be defined with features to match the pushing faces of the extendable mechanisms.
  • the cavities with matching features therein may assist in setting up and assembling the form.
  • the pushing face of the extendable elements may be retractable into the form such that cavities are not necessary, but rather push off will occur directly off the concrete pad, possibly with interface materials to distribute the loading of the extendable mechanisms to a greater surface area of the concrete pad.
  • the interface material may include a plate, possibly made from steel, with a feature on the top face which matches the pushing face of the extendable mechanisms.
  • the initial push-off cavities in the pad may be filled later to complete the surface of the pad.
  • temporarily filled receptacles may be deposited into the hardenable material. These temporarily filled receptacles may be coupled with each other so that vertical spacing between them will be proper and/or consistent as desired. Additionally, a coupling member may allow for proper location with reference to the top of the form. Temporarily filled receptacles may continual be deposited as the form works its way upward forming the building core.
  • the temporarily filled receptacles may define a cavity once the temporary filling is removed.
  • the cavity may have a similar cross section to the temporary support members to be used in a given embodiment.
  • the temporary filled receptacles may have a length substantially similar to the width of the form in the location in which they are deposited. In that manner, after the portion of the building core surrounding the temporarily filled cavity is formed, the temporarily filling may be removed, and the receptacle may define a cavity in which the temporary support member may be supported.
  • a method for creating a structure is provided.
  • the methods disclosed may include any method by which the system embodiments described herein may be used.
  • the methods may include providing a form, where the form includes an inner frame and an outer frame which may at least partially define a space between the inner frame and the outer frame.
  • the method may also include depositing a hardenable substance in the space, where the hardenable substance may form at least a portion of the structure. Reinforcement members, as described above may also be deposited in the hardenable substance during at any stage of the method.
  • the method may further include providing a plurality of extendable mechanisms, where the plurality of extendable mechanisms may be coupled with the form.
  • the method may further include extending the extending the plurality of extendable mechanisms such that the form may be moved from a first elevation, possibly at substantially ground level, to a second elevation, possibly at least some amount above ground level.
  • the method may additionally include supporting the plurality of extendable mechanisms from one or more walls of the structure. In some embodiments, this may include depositing a plurality of temporary support receptacles in the space where the hardenable material is deposited, where the plurality of temporary support receptacles define a plurality of cavities. Temporary support members may then be supported by the temporary support receptacles. As discussed above, the temporary support receptacles may be temporarily filled with a substance so that hardenable material does not undesirably fill the temporary support receptacle prior to their usage to support temporary support members.
  • Supporting the plurality of extendable mechanisms may include retracting at least a particular number of the plurality of extendable mechanisms and supporting them from temporary support members. Once these particular number of the plurality of extendable mechanisms are supported by the temporary support members, the remainder of the plurality of extendable mechanisms may be retracted and also supported by the temporary support members.
  • the extendable mechanisms coupled with the inner frame may be first retracted in a lifting cycle, with the extendable mechanisms coupled with the outer frame retracted after the inner frame extendable mechanisms are supported at a higher elevation.
  • the outer frame extendable mechanisms may first be retracted.
  • some combination of inner frame and outer frame extendable mechanisms may first be retracted, with the remainder of extendable mechanisms retracted thereafter. In this or other manners, the form may be moved from one elevation to another higher elevation. The method may be repeated until the proper height of building core is accomplished.
  • methods of the invention may also include depositing a first plurality of floor support receptacles in the space during depositing of hardening substance in the space.
  • the first plurality of floor support receptacles may be configured to at least partially support a first plurality of floor support members, and the first plurality of floor support members may be configured to at least partially support a first floor around the structure.
  • a second plurality of floor support receptacles may also be deposited in the space with the hardenable substance. Similar to the first plurality of floor support receptacles, the second plurality of floor support receptacles may also be used as described above to support another floor.
  • U.S. patent application Ser. No. 11/757,899 filed Jun. 4, 2007 and entitled “Floor Support Systems and Methods,” as incorporated above, discusses some possible systems and methods for implementing floor support receptacles and floor support members.
  • a system for creating a structure may include at least portions of the systems for slip forming a building core as described above, systems which implement at least portions of the methods described above, and/or other systems.
  • the system may include at least a first means, a second means, and a third means.
  • the first means may be for at least partially defining a space, where the space may be configured to accept a hardenable substance.
  • the hardenable substance may form at least a portion of the structure.
  • the first means may, merely by way of example, include the form described above, and/or any other component described herein.
  • the second means may be for providing support from a plurality of locations on at least one wall of the structure.
  • the second means may, merely by way of example, include the temporary support members described above, the temporary support receptacles described above, and/or any other component described herein.
  • the third means may be for moving the first means away from the second means such that the first means may be moved from a first elevation to a second elevation, where the third means may be coupled with the first means and supported by the second means.
  • the third means may, merely by way of example, include the extendable mechanisms described above, and/or any other component described herein.
  • FIG. 1 is an axonometric view of a concrete pad 100 prepared prior to slip forming.
  • the concrete pad may be at least partially supported by the ground and may have foundational elements such as caissons.
  • cavities 110 may be defined which provide support bearing members for the initial push off from ground level of the form.
  • Each “set” of cavities 110 may be configured to accept the push face of the extendable mechanisms of the slip form system at matching-position inner frame and outer frame extendable mechanisms.
  • FIG. 1A shows a side sectional view of the support bearing cavities 110 .
  • Cavity 110 may include an embedded or otherwise deposited temporary support member 120 . At least the top portion of the temporary support member 120 may have a cross sectional shape which substantially matches the pushing face 130 of the extendable mechanisms of the slip forming system.
  • FIG. 2 is an axonometric exploded view of a disassembled slip forming system 200 .
  • Slip forming system 200 may include end outer sub-frame components 205 , side outer sub-frame components 210 , and corner outer sub-frame components 215 . Each corner outer sub-frame component 215 may include an extendable mechanism 220 .
  • Slip forming system 200 may also include end inner sub-frame components 225 , side inner sub-frame components 230 , and corner inner sub-frame components 235 . Each corner inner sub-frame component 235 may include an extendable mechanism 220 . Only some of the extendable mechanisms 200 are shown in FIG. 2 for the sake of clarity.
  • matching cavities 240 may be provided at sub-frame interfaces in various numbers and locations to accept joint members 245 .
  • Joint members 245 may at least partially assist in properly aligning adjacent sub-frame components.
  • flanges 250 may provide matching surfaces at adjacent sub-frame components to coupled sub-frame components using fastening mechanisms, for example, nuts and bolts. Proper alignment of adjacent sub-frame components may at least partially assist in aligning the walls of the inner space of the form such that smoother, more consistent walls may be slip formed.
  • FIG. 3 is an axonometric assembled view of the assembled slip forming system 300 from FIG. 2 on the concrete pad 100 from FIG. 1 .
  • FIG. 4 is a plan view of FIG. 3 .
  • both outer frame 310 and inner frame 320 are shown assembled.
  • bridge members 330 are also shown in FIG. 3 . Any number of bridge members 330 may be employed to at least assist in keeping the inner frame 320 stationary relative to the outer frame 330 .
  • Bridge members 330 may be easily removable/re-attachable during forming operations to clear the area above the pour space 340 for assembly of reinforcement members. Note that FIG. 4 does not show bridge members 330 .
  • extendable mechanisms 220 are supported and properly mate with support bearing cavities 110 .
  • FIG. 5 is an axonometric view of the slip forming system 300 from FIG. 3 , after it has begun to form the lower part of the building core 510 . While still at ground level system 300 may have accepted concrete or another hardenable substance to form building core 510 . Frame-out 520 for elevator door openings, and frame-out 530 for stairwell door openings may be deposited into pour space 340 during pouring so that they may be removed from finished building core 510 at a later time during construction.
  • temporary support members 540 support extendable mechanisms 220 .
  • Temporary support members 540 may be supported by temporary support receptacles 550 which were inserted into form 300 during pouring.
  • Extendable mechanisms 220 may be extended while supported by temporary support members 540 until they are at some maximum or other set distance of extension. Then at least some of the extendable mechanisms 220 may be retracted and supported at higher place temporary support members 540 . The remaining extendable mechanisms 220 may then be retracted and supported from temporary support members 540 at the same elevation as the other extendable mechanisms 220 .
  • FIG. 6 is an axonometric view of the slip forming system 300 from FIG. 5 , after it has formed more of the building core 510 .
  • slip forming system 300 has advanced higher than shown in FIG. 5 , forming more of building core 510 .
  • the floor support receptacles 610 are also shown in FIG. 6 .
  • Floor support receptacles 610 may be filled with a temporary substance until they are emptied to support a floor support member used to support a floor surrounding building core 510 .
  • FIG. 7 is an axonometric view of the complete building core 700 from FIG. 6 . In FIG. 6 , building core 700 is shown as being able to provide for a five story building.
  • multiple complete building cores 700 may be provided in a single building.
  • multiple forms 300 may be coupled together during forming of multiple building cores to at least assist in ensuring building cores are vertically straight and/or parallel.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

According to the invention, a system for slip forming a building core is disclosed. The system may include a form and a plurality of extendable mechanisms. The form may include an inner and outer frame. The outer frame and the inner frame may define a space between the inner frame and the outer frame. The form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form the building core. Each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection. The first end may be coupled with the form. The second end may be configured to be supported with a wall of the building core. The extendable midsection may be configured to change the distance between the first end and the second end so the form may be moved to a different elevation.

Description

    BACKGROUND OF THE INVENTION
  • This invention relates generally to building construction. More specifically the invention relates to systems and methods of creating vertical core structures about which buildings may be built.
  • Typical slip forming systems known in the art are custom manufactured on site by carpenters per engineering plans for different size building cores. Even after constructed, more materials, besides those actually used to construct the building core, are necessary for the slip form to advance upward to create the building core.
  • Furthermore, access to the top of the slip forming systems is impeded, making insertion of reinforcement and building-feature components difficult, if not impossible. The systems and methods of the present invention provide solutions to these and other problems.
  • BRIEF DESCRIPTION OF THE INVENTION
  • In one embodiment, a system for slip forming a building core is provided. The system may include a form and a plurality of extendable mechanisms. The form may include an inner frame and an outer frame. The outer frame and the inner frame may at least partially define a space between the inner frame and the outer frame. The form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form at least a portion of the building core. Each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection. The first end may be coupled with the form, the second end may be configured to be supported with a wall of the building core, and the extendable midsection may be configured to change the distance between the first end and the second end such that the form may be moved from a first elevation to a second elevation.
  • In another embodiment, a method for creating a structure is provided. The method may include providing a form, where the form includes an inner frame and an outer frame which may at least partially define a space between the inner frame and the outer frame. The method may also include depositing a hardenable substance in the space, where the hardenable substance may form at least a portion of the structure. The method may further include providing a plurality of extendable mechanisms, where the plurality of extendable mechanisms may be coupled with the form. The method may additionally include supporting the plurality of extendable mechanisms from one or more walls of the structure. The method may furthermore include extending the extendable mechanism such that the form may be moved from a first elevation to a second elevation.
  • In another embodiment, a system for creating a structure is provided. The system may include a first means, a second means, and a third means. The first means may be for at least partially defining a space, where the space may be configured to accept a hardenable substance. The hardenable substance may form at least a portion of the structure. The second means may be for providing support from a plurality of locations on at least one wall of the structure. The third means may be for moving the first means away from the second means such that the first means may be moved from a first elevation to a second elevation, where the third means may be coupled with the first means and supported by the second means.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The present invention is described in conjunction with the appended figures:
  • FIG. 1 is an axonometric view of a concrete pad prepared prior to slip forming;
  • FIG. 1A is a side sectional view of a support bearing cavity on the form of FIG. 1;
  • FIG. 2 is an axonometric exploded view of a slip forming system;
  • FIG. 3 is an axonometric assembled view of the slip forming system in FIG. 2 on the concrete pad from FIG. 1;
  • FIG. 4 is a plan view of FIG. 3;
  • FIG. 5 is an axonometric view of the slip forming system from FIG. 3, after it has begun to form the lower part of the building core;
  • FIG. 6 is an axonometric view of the slip forming system from FIG. 5, after it has formed more of the building core; and
  • FIG. 7 is an axonometric view of the complete building core from FIG. 6.
  • In the appended figures, similar components and/or features may have the same numerical reference label. Further, various components of the same type may be distinguished by following the reference label by one or more letters which distinguishes among the similar components and/or features. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label irrespective of the lettered suffix.
  • DETAILED DESCRIPTION OF THE INVENTION
  • The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing one or more exemplary embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the appended claims.
  • Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, systems, structures, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known processes, procedures and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
  • Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process may be terminated when its operations are completed, but could have additional steps not included in a figure. A process may correspond to a method, a process, a procedure, a technique, etc. Furthermore, embodiments may be implemented by manual techniques, automatic techniques, or any combination thereof.
  • In one embodiment, a system for slip forming a building core is provided. The system may include a form and a plurality of extendable mechanisms. The form may provide a space for accepting a hardenable substance, for example, concrete, and the plurality of extendable mechanisms may move the form to higher elevations once lower elevations of the building core is formed. While building cores will be discussed, the systems disclosed herein may be used to manufacture any number of different structures, especially vertical structures with an at least semi-consistent horizontal cross section. Furthermore, in some embodiments, floors of a building surrounding the building cores produced by the systems and methods of the invention may be supported at least in part by the building core.
  • Merely by way of example, the types of floors and buildings in which embodiments of the invention may be employed are described in U.S. patent application Ser. No. 11/746,834, filed May 10, 2007 and entitled “Multi-Story Building,” and U.S. patent application Ser. No. 11/757,899 filed Jun. 4, 2007 and entitled “Floor Support Systems and Methods.” The entire contents of both of these applications are hereby incorporated by reference for all purposes. Different types of walls which may be installed on the floors of buildings are described in U.S. patent application Ser. No. 11/766,040, filed Jun. 20, 2007 and entitled “Curtain Wall Systems and Methods,” the entire contents of which are hereby incorporated by reference for all purposes.
  • In some embodiments, the forms discussed herein may include an inner frame and an outer frame. The outer frame and the inner frame may at least partially define a space between the inner frame and the outer frame. The form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form at least a portion of the building core.
  • In some embodiments, the inner frame and/or the outer frame of the form may be constructed from a variety of materials, including, but not limited to, metals (i.e. steel), polymers (i.e. plastics), ceramics, composites, and/or cellular materials (i.e. wood). In an exemplary embodiment, fiberglass tubing and sheeting may be molded, fused, or otherwise joined together to create the inner frame and/or the outer frame. In some embodiments, metallic, possibly steel and/or aluminum, reinforcement members may be fiberglassed into the inner frame and/or the outer frame. Additionally, various external features of the inner frame and/or the outer frame may also include metallic elements.
  • In some embodiments, the inner frame and the outer frame may each, or combined, be a singular piece, or include multiple sub-parts. In an exemplary embodiment, the inner frame and/or the outer frame may include a plurality of sub-frame components. The sub-frame components may be configured to be reversibly assembled and disassembled, thereby easing transportation and assembly at a job site. In some embodiments, either one or both of the inner form and the outer form may include a plurality of end sub-frame components, a plurality of side sub-frame components, and a plurality of corner sub-frame components.
  • In some embodiments, the inner frame and/or the outer frame may have pre-drilled or otherwise defined apertures for coupling finishing sheeting with the walls of the space where the hardenable substance is to be deposited. Merely by way of example, plywood and/or other composite/cellular sheets may be coupled with the walls of the space where the hardenable substance is to be deposited via screws and/or other fasteners via pre-drilled apertures passing through the walls of the inner form and the outer form.
  • In some embodiments, the extendable mechanisms may be coupled with the corner sub-frame components of either one or both of the inner frame and the outer frame. Thus, in some of the embodiments discussed, the end sub-frame components and the side end-frame components may be substantially two sided, flat, and light-weight. Meanwhile, the corner end-frame components may carry the more substantial weight of the extendable mechanisms. In an exemplary embodiment, standardized corner sub-frame components may be used with differently dimensioned end sub-frame components and side sub-frame components to allow for the creation of different size building cores merely by altering which side sub-frame components and end sub-frame components are used with the corner sub-frame components having the extendable mechanisms.
  • In some embodiments, joint members may be inserted into cavities in each adjacent sub-frame component to at least assist in joining such adjacent sub-frame components. Different adjacent sub-frame components may have differing number of cavities for differing number of joint members to be used to connect those adjacent sub-frame components. In some embodiments, flanges on the exterior of the outer frame sub-frame components, as well as flanges on the interior of the inner frame sub-frame components may allow for fasteners or other mechanisms to couple adjacent sub-frame components. Any other mechanism known in the art or otherwise may also be used to couple adjacent sub-frame components.
  • In some embodiments, at least one bridge member may be coupled with the inner frame and the outer frame such that the inner frame remains substantially stationary relative to the outer frame. Bridge members may be reversibly coupled so that they may be attached/detached with the form as needed during assembly, use, or disassembly. In some embodiments, the bridge member or members may be configured to allow a reinforcement member to be deposited beneath the at least one bridge member in the space. Reinforcement members may, merely by way of example, include rebar, rebar cages, or wire mesh.
  • In some embodiments, each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection. The first end may be coupled with the form, the second end may be configured to be supported with a wall of the building core, and the extendable midsection may be configured to change the distance between the first end and the second end such that the form may be moved from a first elevation to a second elevation. In this manner, by selective extension and/or retraction of the extendable midsection, the second end of the extendable mechanisms may be pushed away or pulled toward the first end, which may be fixedly coupled with the form.
  • In an exemplary embodiment, one or more of the extendable mechanisms may be hydraulic cylinders. In other embodiments, one or more of the extendable mechanisms may be pneumatic cylinders and/or mechanical jacking systems (i.e. screw jacks or ratcheting jacks). In some embodiments, the power source for the extendable mechanisms may be provided at ground level, or may be self contained and coupled with the form, for example, on a operator working level coupled with the top, middle and/or bottom of the form.
  • In some embodiments, the plurality of extendable mechanisms may include two sets of extendable mechanisms. A first set of extendable mechanisms may be coupled with the inner frame of the form, and a second set of extendable mechanisms may be coupled with the outer frame of the form. The two sets of extendable mechanisms may be aligned such that each extendable mechanism in the first set is linearly aligned with an extendable mechanism in the second set.
  • In some embodiments, the pushing faces of the second end of the extendable mechanisms may be contoured to match a temporary support member that will be used to provide a jacking point on the wall of the building core. In some embodiments, the pushing faces may be flat and/or have a depressed or protruded feature. In these embodiments, the temporary support members may be flat and/or have a protruded or depressed feature, respectively, to match the pushing faces. In an exemplary embodiment, the pushing faces of the second end of the extendable mechanisms may define a cavity having a circular cross section. In these embodiments, the temporary support members may have a circular cross section. In some embodiments, combinations of different pushing faces on different extendable mechanisms may be employed.
  • In some embodiments, initial push-off from ground level may include providing a concrete pad from which the building core will be supported. The concrete pad may also have foundational elements such as concrete caissons. On the top of the concrete pad, cavities may be defined with features to match the pushing faces of the extendable mechanisms. In these embodiments, the cavities with matching features therein may assist in setting up and assembling the form. In other embodiments, the pushing face of the extendable elements may be retractable into the form such that cavities are not necessary, but rather push off will occur directly off the concrete pad, possibly with interface materials to distribute the loading of the extendable mechanisms to a greater surface area of the concrete pad. Merely by way of example, the interface material may include a plate, possibly made from steel, with a feature on the top face which matches the pushing face of the extendable mechanisms. In embodiments with push-off cavities, the initial push-off cavities in the pad may be filled later to complete the surface of the pad.
  • In some embodiments, during the initial pouring of hardenable material into the space of the form, temporarily filled receptacles may be deposited into the hardenable material. These temporarily filled receptacles may be coupled with each other so that vertical spacing between them will be proper and/or consistent as desired. Additionally, a coupling member may allow for proper location with reference to the top of the form. Temporarily filled receptacles may continual be deposited as the form works its way upward forming the building core.
  • The temporarily filled receptacles may define a cavity once the temporary filling is removed. The cavity may have a similar cross section to the temporary support members to be used in a given embodiment. Furthermore, the temporary filled receptacles may have a length substantially similar to the width of the form in the location in which they are deposited. In that manner, after the portion of the building core surrounding the temporarily filled cavity is formed, the temporarily filling may be removed, and the receptacle may define a cavity in which the temporary support member may be supported.
  • In another embodiment, a method for creating a structure is provided. In some embodiments, the methods disclosed may include any method by which the system embodiments described herein may be used.
  • In some embodiments, the methods may include providing a form, where the form includes an inner frame and an outer frame which may at least partially define a space between the inner frame and the outer frame. The method may also include depositing a hardenable substance in the space, where the hardenable substance may form at least a portion of the structure. Reinforcement members, as described above may also be deposited in the hardenable substance during at any stage of the method.
  • The method may further include providing a plurality of extendable mechanisms, where the plurality of extendable mechanisms may be coupled with the form. The method may further include extending the extending the plurality of extendable mechanisms such that the form may be moved from a first elevation, possibly at substantially ground level, to a second elevation, possibly at least some amount above ground level.
  • The method may additionally include supporting the plurality of extendable mechanisms from one or more walls of the structure. In some embodiments, this may include depositing a plurality of temporary support receptacles in the space where the hardenable material is deposited, where the plurality of temporary support receptacles define a plurality of cavities. Temporary support members may then be supported by the temporary support receptacles. As discussed above, the temporary support receptacles may be temporarily filled with a substance so that hardenable material does not undesirably fill the temporary support receptacle prior to their usage to support temporary support members.
  • Supporting the plurality of extendable mechanisms may include retracting at least a particular number of the plurality of extendable mechanisms and supporting them from temporary support members. Once these particular number of the plurality of extendable mechanisms are supported by the temporary support members, the remainder of the plurality of extendable mechanisms may be retracted and also supported by the temporary support members.
  • In one embodiment, the extendable mechanisms coupled with the inner frame may be first retracted in a lifting cycle, with the extendable mechanisms coupled with the outer frame retracted after the inner frame extendable mechanisms are supported at a higher elevation. In other embodiments, the outer frame extendable mechanisms may first be retracted. In yet other embodiments, some combination of inner frame and outer frame extendable mechanisms may first be retracted, with the remainder of extendable mechanisms retracted thereafter. In this or other manners, the form may be moved from one elevation to another higher elevation. The method may be repeated until the proper height of building core is accomplished.
  • In some embodiments, methods of the invention may also include depositing a first plurality of floor support receptacles in the space during depositing of hardening substance in the space. The first plurality of floor support receptacles may be configured to at least partially support a first plurality of floor support members, and the first plurality of floor support members may be configured to at least partially support a first floor around the structure. In these embodiments, a second plurality of floor support receptacles may also be deposited in the space with the hardenable substance. Similar to the first plurality of floor support receptacles, the second plurality of floor support receptacles may also be used as described above to support another floor. U.S. patent application Ser. No. 11/757,899 filed Jun. 4, 2007 and entitled “Floor Support Systems and Methods,” as incorporated above, discusses some possible systems and methods for implementing floor support receptacles and floor support members.
  • In another embodiment, a system for creating a structure is provided. The system may include at least portions of the systems for slip forming a building core as described above, systems which implement at least portions of the methods described above, and/or other systems. The system may include at least a first means, a second means, and a third means.
  • The first means may be for at least partially defining a space, where the space may be configured to accept a hardenable substance. The hardenable substance may form at least a portion of the structure. The first means may, merely by way of example, include the form described above, and/or any other component described herein.
  • The second means may be for providing support from a plurality of locations on at least one wall of the structure. The second means may, merely by way of example, include the temporary support members described above, the temporary support receptacles described above, and/or any other component described herein.
  • The third means may be for moving the first means away from the second means such that the first means may be moved from a first elevation to a second elevation, where the third means may be coupled with the first means and supported by the second means. The third means may, merely by way of example, include the extendable mechanisms described above, and/or any other component described herein.
  • The following figures described just one possible embodiment of the invention and are presented for the purposes of illustrating one possible implementation of the systems and methods of the invention.
  • FIG. 1 is an axonometric view of a concrete pad 100 prepared prior to slip forming. The concrete pad may be at least partially supported by the ground and may have foundational elements such as caissons. On the top surface of pad 100, cavities 110 may be defined which provide support bearing members for the initial push off from ground level of the form. Each “set” of cavities 110 may be configured to accept the push face of the extendable mechanisms of the slip form system at matching-position inner frame and outer frame extendable mechanisms. FIG. 1A shows a side sectional view of the support bearing cavities 110. Cavity 110 may include an embedded or otherwise deposited temporary support member 120. At least the top portion of the temporary support member 120 may have a cross sectional shape which substantially matches the pushing face 130 of the extendable mechanisms of the slip forming system.
  • FIG. 2 is an axonometric exploded view of a disassembled slip forming system 200. Slip forming system 200 may include end outer sub-frame components 205, side outer sub-frame components 210, and corner outer sub-frame components 215. Each corner outer sub-frame component 215 may include an extendable mechanism 220. Slip forming system 200 may also include end inner sub-frame components 225, side inner sub-frame components 230, and corner inner sub-frame components 235. Each corner inner sub-frame component 235 may include an extendable mechanism 220. Only some of the extendable mechanisms 200 are shown in FIG. 2 for the sake of clarity.
  • To couple components 205, 210, 215, 225, 230, 235 of the slip forming system 200, various mechanisms may be provided. First, matching cavities 240 may be provided at sub-frame interfaces in various numbers and locations to accept joint members 245. Joint members 245 may at least partially assist in properly aligning adjacent sub-frame components. Second, flanges 250 may provide matching surfaces at adjacent sub-frame components to coupled sub-frame components using fastening mechanisms, for example, nuts and bolts. Proper alignment of adjacent sub-frame components may at least partially assist in aligning the walls of the inner space of the form such that smoother, more consistent walls may be slip formed.
  • FIG. 3 is an axonometric assembled view of the assembled slip forming system 300 from FIG. 2 on the concrete pad 100 from FIG. 1. FIG. 4 is a plan view of FIG. 3. In FIG. 3, both outer frame 310 and inner frame 320 are shown assembled. Also shown in FIG. 3 are bridge members 330. Any number of bridge members 330 may be employed to at least assist in keeping the inner frame 320 stationary relative to the outer frame 330. Bridge members 330 may be easily removable/re-attachable during forming operations to clear the area above the pour space 340 for assembly of reinforcement members. Note that FIG. 4 does not show bridge members 330. Also note in FIG. 3 that extendable mechanisms 220 are supported and properly mate with support bearing cavities 110.
  • FIG. 5 is an axonometric view of the slip forming system 300 from FIG. 3, after it has begun to form the lower part of the building core 510. While still at ground level system 300 may have accepted concrete or another hardenable substance to form building core 510. Frame-out 520 for elevator door openings, and frame-out 530 for stairwell door openings may be deposited into pour space 340 during pouring so that they may be removed from finished building core 510 at a later time during construction.
  • In FIG. 5, temporary support members 540 support extendable mechanisms 220. Temporary support members 540 may be supported by temporary support receptacles 550 which were inserted into form 300 during pouring. Extendable mechanisms 220 may be extended while supported by temporary support members 540 until they are at some maximum or other set distance of extension. Then at least some of the extendable mechanisms 220 may be retracted and supported at higher place temporary support members 540. The remaining extendable mechanisms 220 may then be retracted and supported from temporary support members 540 at the same elevation as the other extendable mechanisms 220.
  • FIG. 6 is an axonometric view of the slip forming system 300 from FIG. 5, after it has formed more of the building core 510. As seen in FIG. 6, slip forming system 300 has advanced higher than shown in FIG. 5, forming more of building core 510. Also shown in FIG. 6 are the floor support receptacles 610. Floor support receptacles 610 may be filled with a temporary substance until they are emptied to support a floor support member used to support a floor surrounding building core 510. FIG. 7 is an axonometric view of the complete building core 700 from FIG. 6. In FIG. 6, building core 700 is shown as being able to provide for a five story building. More or fewer floors may be provided in other embodiments. Additionally, in other embodiments, multiple complete building cores 700 may be provided in a single building. In these or other embodiments, multiple forms 300 may be coupled together during forming of multiple building cores to at least assist in ensuring building cores are vertically straight and/or parallel.
  • The invention has now been described in detail for the purposes of clarity and understanding. However, it will be appreciated that certain changes and to the exemplary embodiments discussed herein may be practiced within the scope of the appended claims.

Claims (22)

1. A system for slip forming a building core, the system comprising:
a form, wherein:
the form includes:
an inner frame; and
an outer frame, wherein the outer frame and the inner frame at least partially define a space between the inner frame and the outer frame; and
the form is configured to accept a hardenable substance in the space, wherein the hardenable substance forms at least a portion of the building core; and
a plurality of extendable mechanisms, wherein each extendable mechanism includes:
a first end, wherein the first end is coupled with the form;
a second end, wherein the second end is configured to be supported with a wall of the building core; and
an extendable midsection configured to change the distance between the first end and the second end such that the form is moved from a first elevation to a second elevation.
2. The system for slip forming a building core of claim 1, wherein the form further includes at least one bridge member, and wherein each bridge member is coupled with the inner frame and the outer frame such that the inner frame remains substantially stationary relative to the outer frame.
3. The system for slip forming a building core of claim 2, wherein the at least one bridge member is configured to allow a reinforcement member to be deposited beneath the at least one bridge member in the space.
4. The system for slip forming a building core of claim 1, wherein the second end being configured to be supported with a wall of the building core comprises the second end being supported by a temporary support member at least partially inserted into a cavity defined at least in part by the wall of the building core.
5. The system for slip forming a building core of claim 4, wherein the temporary support member comprises a member having a circular cross section.
6. The system for slip forming a building core of claim 5, wherein the second end defines a cavity having a circular cross section.
7. The system for slip forming a building core of claim 1, wherein the plurality of extendable mechanisms includes:
a first set of extendable mechanisms; and
a second set of extendable mechanisms; and
wherein the first end being coupled with the form comprises:
the first end of each of the first set of extendable mechanisms coupled with the inner frame; and
the first end of each of the second set of extendable mechanisms coupled with the outer frame.
8. The system for slip forming a building core of claim 1, wherein at least one of the inner frame and the outer frame comprises a plurality of sub-frame components, and wherein the sub-frame components are configured to be reversibly assembled.
9. The system for slip forming a building core of claim 8, wherein the plurality of sub-frame components comprises:
a plurality of end sub-frame components;
a plurality of side sub-frame components; and
a plurality of corner sub-frame components, wherein at least one of the plurality of extendable mechanisms is coupled with at least one of the plurality of corner sub-frame components.
10. The system for slip forming a building core of claim 9, wherein the first end being coupled with the form comprises the first end of each of the plurality of extendable mechanisms coupled with one of the plurality of end sub-frame components.
11. The system for slip forming a building core of claim 1, wherein the hardenable substance comprises concrete.
12. A method for creating a structure, the method comprising:
providing a form, wherein the form includes:
an inner frame; and
an outer frame, wherein the outer frame and the inner frame at least partially define a space between the inner frame and the outer frame; and
depositing a hardenable substance in the space, wherein the hardenable substance forms at least a portion of the structure;
providing a plurality of extendable mechanisms, wherein the plurality of extendable mechanisms are coupled with the form;
supporting at least some of the plurality of extendable mechanisms from one or more walls of the structure; and
extending the extendable mechanism such that the form is moved from a first elevation to a second elevation.
13. The method for creating a structure of claim 12, the method further comprising depositing a plurality of temporary support receptacles in the space, wherein the plurality of temporary support receptacles define a plurality of cavities; and
wherein supporting the extendable mechanism from the wall of the structure comprises supporting the plurality of extendable mechanisms with a plurality of temporary support members at least partially inserted into the plurality of cavities.
14. The method for creating a structure of claim 12, the method further comprising depositing at least one reinforcement member in the space.
15. The method for creating a structure of claim 12, the method further comprising depositing a first plurality of floor support receptacles in the space, wherein the first plurality of floor support receptacles are configured to at least partially support a first plurality of floor support members, and wherein the first plurality of floor support members are configured to at least partially support a first floor around the structure.
16. The method for creating a structure of claim 15, the method further comprising:
coupling a second plurality of floor support receptacles with the first plurality of floor support receptacles; and
depositing the second plurality of floor support receptacles in the space, wherein the second plurality of floor support receptacles are configured to at least partially support a second plurality of floor support members, and wherein the second plurality of floor support members are configured to at least partially support a second floor around the structure.
17. The method for creating a structure of claim 12, wherein supporting the plurality of extendable mechanisms from one or more walls of the structure comprises supporting the plurality of extendable mechanisms from one or more walls of the structure at a third elevation; and
wherein the method further comprises supporting the plurality of extendable mechanisms from a surface at a fourth elevation, wherein the third elevation is higher than the fourth elevation.
18. The method for creating a structure of claim 12, the method further comprising:
retracting a particular number of the extendable mechanisms, leaving a remaining number of the extendable mechanisms supported by one or more walls of the structure at a third elevation;
supporting the particular number of extendable mechanisms at a fourth elevation; and
extending the particular number of extendable mechanisms.
19. A system for creating a structure, the system comprising:
a first means for at least partially defining a space, wherein the space is configured to accept a hardenable substance, and wherein the hardenable substance forms at least a portion of the structure;
a second means for providing support from a plurality of locations on at least one wall of the structure; and
a third means for moving the first means away from the second means such that the first means is moved from a first elevation to a second elevation, wherein the third means is coupled with the first means and supported by the second means.
20. The system for creating a structure of claim 19, wherein the first means comprises a form.
21. The system for creating a structure of claim 19, wherein the second means comprises a plurality of temporary support members.
22. The system for creating a structure of claim 19, wherein the third means comprises a plurality of extendable mechanisms.
US11/843,464 2007-08-22 2007-08-22 Building Core Slipform Abandoned US20090049762A1 (en)

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