US3922832A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Construction method of assembling bagged, settable modules
Assignee: Individual
•
Filing: 1973-07-23
•
Granted: 1975-12-02
•
Expires: 1993-07-23
Abstract
Abstract Discrete structural construction units comprising porous sacks containing a dry premixed fill of aggregate, sand and cement are arranged in juxtaposed relation to form a horizontal course of a wall, and water is applied to the units to activate the fill therein to form an integrated structure. Successive courses of the structural units are superimposed on each other, including wetting the units in the courses, to form a completed, integrated structural wall. A building structure is constructed by excavating suitable trenches for the foundation, filling the trenches to ground level with concrete to form foundation beams, arranging at least one course of the structural units on the outer foundation beams, including wetting the units of this course to set up, pouring a concrete slab floor within the confines of the outer foundation beam using the course of structural units as a form, laying successive courses to complete the structural walls of the building, blowing a concrete skin on the surfaces of the wall, and adding a roof thereto.
Inventors
- 👤 Edward T Dicker
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 13:53
CPC Classifications
E; E04; E04B; E04B1/00; E04B1/16; E04B1/167; E04B1/168; C; C04; C04B; C04B40/00; C04B40/06; C04B40/0608; E04B1/38; E04B1/48; E04B1/49; E04B2/00; E04B2/84; E04H; E04H9/00; E04H9/04; E04H9/10; F; F16; F16B; F16B15/00; F16B15/0023; F16B15/003; F16B15/0038; C04B2103/00; C04B2103/0068; C04B2103/0077; F16B2015/0069
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
190 words
The method of building a monolithic homogeneous structural wall suitAble for housing structures comprising the steps of: a. forming a horizontally disposed foundation beam having vertically extending rods protruding therefrom; b. forming discrete construction units comprising a dry mixture contained within uniformity porous containers which, when wetted, are activated to set up as hardened structural members; c. arranging said construction units in superimposed courses on said horizontal foundation beam, said vertically extending rods extending through at least the first course of said construction units; d. wetting each of said construction units to activate said mixture to set up and form an integrated homogeneous structure with continuous bonds between adjacent containers; e. driving vertical reinforcing rods into the construction units in the later formed courses so that said reinforcing rods overlap the said vertically extending rods protruding from the foundation beam within the wall structure; and f. applying a skin of concrete onto at least one side of the superimposed courses under substantial pressure so that the skin bonds to said mixture through the pores in the containers, whereby said skin and said superimposed courses form an integral, homogenous monolithic structure.
Claim 2
Independent Claim
190 words
The method of building a monolithic homogeneous structural wall suitAble for housing structures comprising the steps of: a. forming a horizontally disposed foundation beam having vertically extending rods protruding therefrom; b. forming discrete construction units comprising a dry mixture contained within uniformity porous containers which, when wetted, are activated to set up as hardened structural members; c. arranging said construction units in superimposed courses on said horizontal foundation beam, said vertically extending rods extending through at least the first course of said construction units; d. wetting each of said construction units to activate said mixture to set up and form an integrated homogeneous structure with continuous bonds between adjacent containers; e. driving vertical reinforcing rods into the construction units in the later formed courses so that said reinforcing rods overlap the said vertically extending rods protruding from the foundation beam within the wall structure; and f. applying a skin of concrete onto at least one side of the superimposed courses under substantial pressure so that the skin bonds to said mixture through the pores in the containers, whereby said skin and said superimposed courses form an integral, homogenous monolithic structure.
Claim 3
Dependent Claim
43 words
The method set forth in claim 1 wherein said discrete construction units are wetted immediately prior to arranging them in superimposed coursed by immersing said construction units in water for a period of time ranging from about 3 seconds to about 25 seconds.
Claim 4
Dependent Claim
39 words
The method set forth in claim 1 wherein said discrete construction units are wetted after arranging said units in courses by applying water to the top only of the units in each course before arranging each succeeding course thereon.
Claim 5
Dependent Claim
105 words
The method set forth in claim 1 wherein said horizontal foundation beam defines the outer walls of a habitable structure and is wider than the width of said construction units, including the steps of: a. positioning the first course of said construction units near the center of said foundationn beam, thereby leaving a portion of the surface of the foundation beam within the confines of the wall exposed; and b. pouring concrete within the area defined by said first course of construction units to provide a concrete slab overlying the portion of the surface of said foundation beam within the confines of said wall structure.
Claim 6
Dependent Claim
78 words
The method set forth in claim 1 wherein said horizontally disposed foundation beams are formed by: a. excavating a trench over which said structural wall is to be constructed; b. filling said trench to approximately ground level with concrete; c. inserting said vertically extending rods into said concrete before said concrete hardens; d. allowing the concrete in said trench to harden; and e. wetting the surface of said foundation beams immediately prior to arranging said construction units thereon.
Claim 7
Dependent Claim
28 words
The method set forth in claim 1 including the step of spraying said wall with water at least four times within the first 48 hours after its construction.
Claim 8
Dependent Claim
57 words
The method set forth in claim 3 wherein said dry mixture comprises aggregate, sand and cement, and said units are wetted by applying water to the top only of said units in an amount sufficient to activate said cement throughout said units but to permit only a predetermined maximum amount of slump in said units when activated.
Claim 9
Dependent Claim
28 words
The method set forth in claim 1 wherein said skin of concrete is sprayed onto said superimposed cources under a pressure of about 60 l to 80 psi.
Claim 10
Independent Claim
112 words
A method of constructing a monolithic wall suitable for housing structures using discrete construction units comprising a dry mixture contained within porous containers which, when wetted, are activated to set up as hardened structural members, comprising the steps of: a. arranging said construction units in superimposed courses; b. wetting each of said units to activate said mixture to set up and form an integrated structure; and c. applying a skin of finishing material onto the side of the superimposed courses under substantial pressure so that said finishing material is bonded directly to said mixture through the pores in said containers and said skin and said superimposed courses form an integral monolithic structure.
Claim 11
Independent Claim
112 words
A method of constructing a monolithic wall suitable for housing structures using discrete construction units comprising a dry mixture contained within porous containers which, when wetted, are activated to set up as hardened structural members, comprising the steps of: a. arranging said construction units in superimposed courses; b. wetting each of said units to activate said mixture to set up and form an integrated structure; and c. applying a skin of finishing material onto the side of the superimposed courses under substantial pressure so that said finishing material is bonded directly to said mixture through the pores in said containers and said skin and said superimposed courses form an integral monolithic structure.
Claim 12
Dependent Claim
20 words
A method as set forth in claim 9 wherein said construction units are arranged in juxtaposed positions along each course.
Claim 13
Dependent Claim
32 words
A method as set forth in claim 9 including the step of inserting reinforcing members in said construction units when arranged in said courses to interconnect adjacent units with said reinforcing members.
Claim 14
Dependent Claim
41 words
A method as set forth in claim 9 including the step of driving a plurality of reinforcing rods through each of said construction units when arranged in a course so that said rods protrude into adjacent units in an underlying course.
Claim 15
Dependent Claim
41 words
The method as set forth in claim 9 wherein said units comprising a dry mixture contained within porous containers are arranged in juxtaposed positions along each course and water is applied to the entire course to wet each of said units.
Claim 16
Dependent Claim
86 words
A method as set forth in claim 9 including the steps of excavating a trench over which said integrated structure is to be constructed as a wall, pouring concrete in said trench to form a concrete beam, arranging said construction units in juxtaposition in said superimposed courses on said concrete beam, the wet mixture permeating the containers and bonding with the concrete beam so that said beam constitutes an integral part of said structure, and securing a roof structure to the top of said wall structure.
Claim 17
Dependent Claim
56 words
A method as set forth in claim 14 including the step of inserting steel reinforcing members in said concrete beam to protrude thereabove, impaling the construction units of the first course on said rods, and inserting additional reinforcing members in said units when arranged in succeeding courses to interconnect adjacent units with said additional reinforcing members.
Claim 18
Dependent Claim
56 words
A method as set forth in claim 9 wherein said mixture comprises aggregate, sand and cement, said courses are wetted by applying water to the top only of said units in an amount sufficient to activate said cement throughout said units but to permit only a predetermined maximum amount of slump in said units when activated.
Claim 19
Dependent Claim
27 words
A method as set forth in claim 16 wherein said slump is detected visually so that the amount of water applied to said units can be controlled.
Claim 20
Dependent Claim
104 words
A method as set forth in claim 9 including the steps of inserting a first pair of reinforcing rods in each construction unit that are also inserted in an adjacent pair of said units, respectively, immediately underlying said each construction unit to tie said each construction unit to each of said adjacent pair of said underlying units, and inserting a second pair of reinforcing rods in said each construction unit that are also inserted in an adjacent pair of said units, respectively, immediately overlying said each construction unit to tie said each construction unit to each of said adjacent pair of said overlying units.
Claim 21
Dependent Claim
94 words
A method as set forth in claim 9 wherein said mixture comprises aggregate, sand and cement, including the steps of blowing onto the sides of a first plurality of said superimposed courses after being arranged and wetted a skin of concrete under substantial pressure so that said skin penetrates voids in said sides and keys to the concrete through said porous containers to reinforce said first plurality of superimposed courses, and thereafter successively arranging and wetting further superimposed courses thereabove and blowing said skin onto the sides thereof to progressively construct a wall structure.
Claim 22
Dependent Claim
21 words
A method as set forth in claim 19 including the step of applying a finishing coat of material onto said skin.
Claim 23
Dependent Claim
37 words
A method as set forth in claim 9 wherein said porous containers comprise sacks having seams along the end and Said superimposed courses of said units are arranged by positioning said sacks with said seams being vertical.
Claim 24
Independent Claim
306 words
A method of constructing a building using discrete construction units comprising a dry mixture of sand, aggregate and cement contained within porous containers that upon wetting are activated to set up as hardened structural members, comprising the steps of: a. excavating trenches over which the exterior and interior walls of said building are to be erected; b. filling said trenches to ground level with concrete to form concrete foundation beams; c. arranging said construction units in juxtaposed positions on the foundation beam corresponding to the exterior walls of said building to form at least one course of said exterior walls thereon; d. wetting each of said construction units so arranged to activate said mixture to set up as hardened structural members, the wet mixture permeating the containers and forming a continuous integral monolithic structure through the pores of adjacent containers and with said concrete foundation beams; e. pouring concrete within the confines of said foundation beam corresponding to said exterior walls against said at least one course of structural members acting as a form to provide a slab overlying said foundation beams corresponding to said interior walls; f. arranging additional of said construction units in juxtaposed positions and in superimposed courses on said at least one course to form said exterior walls of the desired height; g. blowing onto the sides of a first plurality of said superimposed courses after being arranged on said foundation beam corresponding to said exterior walls and wetted a skin of concrete under substantial pressure so that said skin penetrates voids in said sides and keys to the concrete through said porous containers to reinforce said plurality of superimposed courses, and thereafter blowing said skin onto the sides of successively arranged pluralities of said courses as said exterior walls are erected; and h. constructing a roof structure over said exterior walls.
Claim 25
Independent Claim
306 words
A method of constructing a building using discrete construction units comprising a dry mixture of sand, aggregate and cement contained within porous containers that upon wetting are activated to set up as hardened structural members, comprising the steps of: a. excavating trenches over which the exterior and interior walls of said building are to be erected; b. filling said trenches to ground level with concrete to form concrete foundation beams; c. arranging said construction units in juxtaposed positions on the foundation beam corresponding to the exterior walls of said building to form at least one course of said exterior walls thereon; d. wetting each of said construction units so arranged to activate said mixture to set up as hardened structural members, the wet mixture permeating the containers and forming a continuous integral monolithic structure through the pores of adjacent containers and with said concrete foundation beams; e. pouring concrete within the confines of said foundation beam corresponding to said exterior walls against said at least one course of structural members acting as a form to provide a slab overlying said foundation beams corresponding to said interior walls; f. arranging additional of said construction units in juxtaposed positions and in superimposed courses on said at least one course to form said exterior walls of the desired height; g. blowing onto the sides of a first plurality of said superimposed courses after being arranged on said foundation beam corresponding to said exterior walls and wetted a skin of concrete under substantial pressure so that said skin penetrates voids in said sides and keys to the concrete through said porous containers to reinforce said plurality of superimposed courses, and thereafter blowing said skin onto the sides of successively arranged pluralities of said courses as said exterior walls are erected; and h. constructing a roof structure over said exterior walls.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-12-01 | 1979-06-02 | 1979-12-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-12-01 | 1983-06-02 | 1983-12-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-12-01 | 1987-06-02 | 1987-12-02 | $7700.00 | Window Closed / Lapsed |