CA2970006A1 - Superblock building method""superblock building system"hurricane homes - Google Patents

Description

Patent Request June 9th 2017 To the officer, of the Canadian Intellectual property office.
I am Clayton L Thomas, I am born in Vancouver Canada, I am a citizen of Canada, and I am requesting a patent for my invention, Called "SuperBlock Building Method".
My address is: 209 Murtle Rd Clearwater BC VOE 1N1 This invention was witnessed in August of 2016 but not disclosed publicly (except to several witnesses) and not sold.
I am seeking a patent under the small entity application method, and will add more to the modes and embodiments of the invention as I have more time.
The invention is as follows. I have described here, through drawings and diagrams, a method by which a building envelope might be built, using a new method, including inherently STABLE
blocks, with dimensions of width and length equal to or wider than the height.
The block system is PREFINISHED INSIDE, and OUT, it is preferred to be made with resources OTHER than wood, and may be made by very available resources, INCLUDING but not LIMITED
TO, recycled materials, sand, recycles aluminum, aluminum slag, recycled metal scrap, plastics, sand, cement, stone, tile and even cardboard, or plastics for the conduits.
This block, is unique, in that it is made with a "box" which contains hollow passageways for conduits to pass, BOTH
HORIZONTALLY and VERTICALLY, these passageways permit ALIGNING TUBES to be EQUALLY SPACED, and LINED UP with each other, as the blocks are STACKED one upon the other. THE SYSTEM MAY BE MADE OF MANY MATERIALS with preference given to those most durable, strong and environmentally friendly. The example in this patent, is 2ft wide by 2 ft tall by 4 ft long, and another embodiment may be larger, but should generally be wider and longer than the HEIGHT, to enable QUICK RELEASE from the MULTI GRAPPLER
JIB/BOOM
system designed for a CRANE to GRASP and QUICKLY RELEASE, FIVE or MORE blocks at a TIME. This enables 20 Feet or MORE of wall section to be laid at ONE PASS.
Also, the system might have concrete PILLARS poured VERTICALLY, with CONCRETE BOND BEAMS poured HORIZONTALLY, OR The system might be COMPLETELY FILLED WITH CONCRETE, or the system might be filled with INSULATING MATERIALS or the system might be partially filled with INSULATIVE MATERIALS AND CONCRETE, in DESIRED layers, IE either 6 inches of foam insulation, and 14 inches of steel reinforced concrete, OR 20 Inches of CONCRETE without insulation, OR INSULATION of many types possible, with STEEL BOLTED FRAME
INSIDE THE
WALL, inside passage tubes, and ridgid PLATES ON TOP OF EACH WALL SYSTEM, to enable bolting to posts(concrete or steel) inside wall passages, allowing disassembly and reassembly.
Much of this concept can be understood by the TOY called LEGO. This system is far different however, in that it Utilizes modern construction methods materials and a large dimension which is ALSO light enough for a crane to lift groups or single blocks, in one lift.
A typical "lift" is displayed in drawings to follow. The system incorporates also, a LEVELLING
TRACK, with ADJUSTABLE STEEL PINS, which have WIDE FLANGES to Set into the concrete Building Footings, while allowing ADJUSTMENT of LEVEL and PITCH of the initial courses and therefore the entire wall system. THE SYSTEM ALLOWS EITHER PERMANENT OR NON PERMANENT
structures to be built RAPIDLY, with a MINIMUM of waste, ZERO CUTTING and near PERFECT
wall level, plumb, square and straightness. The system also (because of the large regular dimensions of the blocks) allows ONE HALF BLOCK TO EQUAL BLOCK WIDTH, this enables cornering and walls to be EASILY STACKED, without cutting or wasting ANY
MATERIAL. It allows building to be erected in ANY CLIMATE, through mechanization of the building method, through now available CRANES and technology such as BOOM CAMERAS, Lighting, heated operator cab, REMOTE OPERATION OF CRANE, and many other advantages, such as Below Patent Request June 9th 2017 grade SAFETY for construction workers, avoidance of fatal and other accidents due to falling and lifting heavy objects, and due to many hand tools used in the building of the High exterior and interior SHELL walls, and even allows the use of HALF SIZE blocks, for partitions and fast assembly of ROOMS. These blocks have 22 variations, incorporating also a steel header system, and an engineered beam system using SLOTTED BLOCKS to allow the beams to be easily placed into the structure by a crane, and beams may sit on STEEL POSTS
or CONCRETE POSTS/PILLARS WITHIN THE WALLS, or CONCRETE LEDGERS within the walls, OR might be supported further by any posts inside the structural envelope, or OUTSIDE
the envelope. Because the system covers these members within the finish, while still allowing electrical, plumbing, security, gas and other services to PASS THROUGH, even AFTER the wall is filled with concrete, it is workable for all the trades to put appropriate services INSIDE the walls. For example, a 3" hole might be drilled through the wall face, at an intersection of the VERTICAL and HORIZONTAL Conduits (passageways/pipes) and create a junction between the two, allowing TOTAL FLEXIBILITY for installation of services, either before of after concrete is poured, or before or after steel posts and beams are attached. FLOOR BLOCKS
4ft by 4ft size, for example, have conduits, and insulation built in, and a PREFINISHED
UNDERSIDE(ceiling) and a PREFINISHED TOP SIDE (Floor) or PREFINISHED TOPSIDE
(ROOF) with waterproofing and interlocking grooves, which may then covered with any suitable membrane and waterproofed, and then an earthen roof, or metal roof, or framed gable roof, may be chosen as appropriate. The strength of 20 inch thick steel reinforced walls, or of 12 inch steel reinforced pillars at as little as two foot centres, with bond beams at each floor(as a minimum) allow enough strength to place anything desired on the FLAT or SLOPED ROOF.
Additional pillars may be added to support a swimming pool, or roof top gardens, or rooftop PARKING, or any desired combination desired. The pour may be MONOLITHIC and may contain steel, fibreglass strand, acrylic additives, pozzolonic additives or any such mixture as is suitable, and commonly used in concrete today. The INSULATED CONCRETE FORM THAT EXISTS
TODAY, called 1CF, is not prefinished, and contains no inherent structural or balancing stability, no leveler tracks, no interior structural integrity and no passages with conduit.
SUPERBLOCK
incorporates ALL of these features and tongue and groove edges, centering guide plates and other features to be further described, to enable a much more accurate and even more affordable installation, completing the wall exterior and interior at once by crane, and allowing for LARGE conduits, 4 inches or greater in diameter, to be used with a VACUUM
HOSE, and a pin pong ball, on a string, to suck the string to desired interior location of wires or pipes etc, utilizing this string, the wires may be pulled through to the junction, this allowing complete wiring and services to be installed after the build and pour, or after wall assembly and before the pour.
Additionally, the system incorporates a RUBBER PLUG, with a side passage, to stopper the drilled junction hole, and to direct air flow of suction through desired pipes, to attract said ball and string. Finally, another part of the Super Block Building system, incorporates a REMOVABLE WALL FACE block, exterior or interior face attached by screws, catches, magnetic catches, french cleats, or any manner of bolts with flat or recessed heads etc, to be used at wall tops, wall bottoms, electrical panel areas, or anywhere a removable panel may be useful in assembly or after assembly for services to be installed. THESE
REMOVABLE PANELS
are not needed in every situation, and as they are more expensive to make, can be used sparingly, or on exterior areas for future allowance for repairs of damages should that be desirable and allowed by the budget.
FURTHER this system may be used to house EARTH, CLAY or MYCO STRAW insulations which are also environmentally friendly options, and cost effective, while yet allowing a superior structure, fit and finish to these materials as normally used. The system also enables the use of heated and air-conditioned Cranes, remote operators on site or remote operators via internet, to Patent Request June 9th 2017 build structures at all times of day or night, and in hostile environments where weather may slow workers, and other safety factors such as snow, ice, darkness, or heat might interfere with the building schedule. The system could be compared to McDonalds meal preparation VS a meal prepared in kitchen where cutting and preparation must take place for each meal. This system allows a far greater level of quality, and allows for controlled factory conditions in the making of the components. Unlike existing TILT UP wall panels, the system allows inherent stability, (little to no risk of tipping over or killing workers) and unlike tilt up panels, this system is completely ported (has conduits), with passages for services, and a PREFINISHED SURFACE
INSIDE
AND OUT, and several RAPID ALIGNMENT features allowing greater mechanization, easy LIFTING by crane, and EASY ACCURATE, QUICK RELEASE of five or more blocks at a time. If GIANT BLOCKS are used, for example 8ft long by 4 feet thick by 4 ft tall, then a wall can even be assembled 4X faster, to build very large structures for industry, energy, mining, etc. This is particularly useful to create buildings for fast assembly and disassembly for such uses and Huge Equipment in arctic conditions, or Desert conditions. Or anywhere that a reliable, fast, and stable method of construction is desired, or disassembly and site remediation and a high level of worker safety is required. The site "supervisor" or "spotter" can stay safely out of harms way, and the crane can use boom cameras and lighting, sensors and lasers, computer numbering and software, to easily guide each block to its rightful place in the building. BUILD by numbers is a phrase that seems appropriate and modern computer programming software is extremely useful when working with UNIFORM BLOCK SIZES such as here presented in the superblock method. These structures will be durable, water and rot resistant, earthquake resistant, hurricane resistant, fire resistant, ant and termite resistant and extremely energy efficient, both in heating/cooling costs (2 ft thick walls provide ample opportunity for High Insulative Value) and also in building costs, by saving WASTE and labour, and allowing the use of recycled materials, in a way that maintains structural and aesthetic INTEGRITY. Furthermore, these blocks may be used for landscaping, wall retaining, swimming pool or settling pond building, Mine shaft linings, HIGHWAYS barriers, CHIMNEY construction, and might be finished on all sides, to be used as PLANTERS, Earth Retaining Walls, DIVIDERS and any other structural requirements. The pipe /bolt together version of the system is very easy to use, and allows the building to be strong, but also disassembled and reassembled without damages if industry requires it. In environments where the system requires, it can be adapted to each circumstance, by adding more concrete, less insulation, or more insulation less concrete. A 20 inch wide wall cavity allows all this. Further, if a hurricane proof home or flood resistant home is desired, and full two foot thick concrete roof might be poured to enable parking or hurricane /typhoon resistance.
A swimming pool on the roof, could help lower cooling requirements, and even cushion the blow .
of falling objects during violent storms. The thick walls, aside from excellent structural opportunities, can enable pocket doors, windows, sliding shutters, and multiple layered windows to conserve heat, and deep returns protect windows and interior from dirt and flying storm debris, while also being aesthetically pleasing. The four foot long blocks (a prime example of the type of size desired) are pleasing to the eyes, covered with natural sandstone, limestone, plaster, stucco, slate, polished granite or metal, plastics, metal alloys, cement plastic composites and rubber composites are useful in heavy or light industrial applications, where the walls might be quickly assembled for a factory, or for use around heavy equipment or for a very durable finish for heavy and long usage(in an oilfield or Mining Site for instance, or in a logging camp, energy production (power plants)(Dams)(4ft wide, by 4ft tall by 8 feet long) or even larger are ideal for Dams and giant buildings) or many other industrial types of useage. While Insulated Concrete Forms ICF are insulated and DO hold Concreteõ they do not have inherent strength, enough to support a building, neither passages for utilities, neither interior finish, neither exterior finish, neither floor systems, nor adjustable track, nor adaptability to Patent Request June 9th 2017 mechanization. The superblock internal "cages" may interlock with "tabs" or Concrete through passages, or steel through, and because they are strong, and light, in many cases no concrete fill is required, for example a single or two story structure. Other than using metal "box cages" or "Brace clips", other materials can be used in manufacture such as fiberglass and plastic composites, these other materials may be used to create the rigid internal framework, although wood and other degradable materials are less desirable due to less rot, lower water/fire resistance, swelling, checking, curving, knots, warping, and overall less strength. In southern climates, termite and hurricane resistance and even flood resistance are desirable and can be accommodated, and in hot climates easy cooling (pre finished floor panel blocks contain water piping to readily heat or cool the floor surfaces), and in Cold climates, even R45 walls are possible within the 21 or 20 inches of "inside the wall"space. Industrial uses are nearly endless, as are residential and commercial uses. Large greenhouses are also very well suited to the system, as the blocks provide excellent insulation, and with flat roof option can support glass and plastic windows or "skylights" very well.
Farming and agriculture will also very readily find uses for large, well built and customizable or mobile temporary buildings. Existing wall panel systems are not inherently stable, not as customizable and are more difficult to use and transport, while offering less utility overall, and ICF do not offer their own exterior finish, conduits, structural stability or interior finish. This essentially means building two or even THREE walls, instead of one (as with Superblock System). The cutting and fitting operations of traditional construction methods include envelope paper, exterior finishes, interior drywall, insulation and framing ALL REQUIRE
CUTTING. They then require DRILLING for electrical, plumbing, gas fitting, telephone, internet, security, and other services. I am well versed in ALL of these trades, unfortunately I have been exposed to ALL of these disadvantages to this current state of this art. Traditional Chimney building is slow, dangerous, and difficult compared to SuperBlocks crane assisted assembly, as in the SuperBlock system where the liners, opening and exterior finish can all be included in one step, while even allowing concrete and or steel reinforcement to be added inside the chimney where desired, for example on a taller chimney the base may be filled with steel and concrete, around the flues, as desired to satisfy the engineering specifications or building codes..
The advantages continue, when one considers architecture, which I am also familiar with. When designing with traditional materials, measurements often come out ODD, for instance, walls are commonly 9 feet long, or 10 ft 4 and 1/2 inches, which requires tremendous cutting and thus waste of time and labour. It is an easy choice, for both owners and architects, to decide upon 2 foot long increments in design, both vertically and horizontally PRIOR to building, saving MUCH
time in designing, costing and estimating, and the cost saved well justifies the floor space required for the thicker walls, and slight compromise in designs that may be required. Costing is a simple matter as is design, with the SuperBlock Computer Software, an integral part of the system. The system might be used for simply an exterior" shell," assembled by crane to "lockup"
and then suitable carpenters and trades hired to add gables, additional interior services, dividers, cabinets, trims, wood flooring, carpets, decorative features and create any configuration or type of building so desired once the foundation and exterior roof, floors and walls are standing and containing windows and doors. It is well known to those in the art, that nearly any building shape can be assembled from squares, and rectangles, and mixtures of any combinations buildings thereof. This is of course becomes apparent when familiar with the TOY
called Lego. In arctic climates, it could even be conceived of using water to fill these walls, to create an Ice Structure, or in the desert, using nothing, or perhaps SAND to fill the wall structure. This would form yet another wall variation of SuperBlock, which could prove useful and might be disassembled if required, but yet will also be long lasting if remaining in-situ as well.