Systems and methods for manufacturing in-situ hollow core / hollow core analogue slabs, walls, and columns
A use of at least one form insert for in-situ manufacture of a hollow core or hollow core analogue slab, the at least one form insert positioned in a mould defining a monolithic volume in which the hollow core or hollow core analogue slab is manufactured by pouring a cement-based curable material into the monolithic volume to submerge the at least one form insert.
1 . A method of manufacturing a hollow core analogue slab using a plurality of form inserts, the method comprising:
positioning the plurality of form inserts in a monolithic volume defined by the final intended position of the hollow core analogue slab and further comprising structural features of a building, the monolithic volume having a first dimension and a second dimension orthogonal to the first dimension, wherein each form insert extends a first distance of the monolithic volume in the first dimension and extends a second distance of the monolithic volume in the second dimension, wherein the first distance is greater than the second distance, wherein the plurality of form inserts are positioned spaced apart along the second dimension of the monolithic volume, wherein the plurality of form inserts are positioned above a bottom edge of the monolithic volume;
pouring a cement-based curable material into the monolithic volume to submerge the plurality of form inserts, wherein a portion of the cement-based curable material fills a space defined between the bottom edge of the monolithic volume and the plurality of form inserts; and
curing the cement-based curable material around the plurality of form inserts, wherein each of the plurality of form inserts are less dense than the cured cement-based curable material to form the hollow core analogue slab, and wherein the plurality of form inserts remain embedded within the cement-based curable material after the cement-based curable material is cured.
2 . The method of claim 1 wherein at least one of the plurality of form inserts is positioned in the monolithic volume with at least one support.
3 . The method of claim 2 wherein the at least one support is at least one chair.
4 . The method of claim 1 wherein the plurality of form inserts each comprise a rigid structure having a generally cylindrical shape that defines an interface between the at least one insert and the cement-based curable material.
5 . A method of manufacturing a hollow core analogue slab in-situ comprising:
providing a monolithic volume to receive plurality of form inserts, the monolithic volume defining an in-situ desired location of the hollow core analogue slab and further comprising structural features of a building, the monolithic volume having a first dimension and a second dimension orthogonal to the first dimension;
positioning the plurality of form inserts within the monolithic volume and above a bottom edge of the monolithic volume, wherein each form insert extends a first distance of the monolithic volume in the first dimension and extends a second distance of the monolithic volume in the second dimension, wherein the first distance is greater than the second distance, wherein the plurality of form inserts are positioned spaced apart along the second dimension of the monolithic volume;
supporting the plurality of form inserts in a fixed position within the monolithic volume;
pouring a cement-based curable material to fill the monolithic volume to submerge the plurality of form inserts, wherein a portion of the cement-based curable material fills a space between the bottom edge of the monolithic volume and the plurality of form inserts; and
curing the cement-based curable material around the plurality of form inserts, wherein each of the plurality of form inserts are less dense than the cured cement-based curable material to form the hollow core analogue slab, and wherein the plurality of form inserts remain embedded within the cement-based curable material after the cement-based curable material is cured.
6 . The method of claim 5 wherein the plurality of form inserts each comprise a rigid structure having a generally cylindrical shape that defines an interface between the insert and the cement-based curable material.
7 . The method of claim 5 comprising:
before pouring the cement-based curable material, positioning a first plurality of reinforcing bars to extend through the monolithic volume along a plane substantially parallel to the bottom of the monolithic volume; and
positioning a second plurality of reinforcing bars to extend through the monolithic volume along a plane substantially parallel to and above the first plurality of reinforcing bars.
8 . The method of claim 7 comprising:
positioning the first or second plurality of reinforcing bars to extend in a direction substantially parallel to the at least one form insert.
9 . The method of claim 7 comprising:
positioning the plurality of form inserts to extend along a plane between the planes of the first and second plurality of reinforcing bars.
10 . The method of claim 1 , wherein at least one of the plurality of form inserts is made with polystyrene foam, cardboard, wax, paper, plastic, hemp sock, synthetic flashspun high-density polyethylene fibers, polyurethane, rubber, wood, PVC, or a resilient inflated material.
11 . The method of claim 1 , wherein at least one of the plurality of form inserts comprises recycled materials.
12 . The method of claim 11 , wherein the recycled materials comprise recycled polystyrene foam.
13 . The method of claim 5 , wherein at least one of the plurality of form inserts is made with polystyrene foam, cardboard, wax, paper, plastic, hemp sock, synthetic flashspun high-density polyethylene fibers, polyurethane, rubber, wood, PVC, or a resilient inflated material.
14 . The method of claim 5 , wherein at least one of the plurality of form inserts comprises recycled materials.
15 . The method of claim 14 , wherein the recycled materials comprise recycled polystyrene foam.
16 . The method of claim 1 , wherein the first dimension of the monolithic volume comprises a width of the monolithic volume and the first distance of each form insert is equal to the width of the monolithic volume.
17 . The method of claim 5 , wherein the first dimension of the monolithic volume comprises a width of the monolithic volume and the first distance of each form insert is equal to the width of the monolithic volume.