A reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, and method for the construction thereof

Abstract

The invention relates to a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, comprising a pre-formed main cast stone body integrally provided with a pre-fabricated reinforcing structural framework to which other structural element is attached, and a means for mounting said structure. A detachable and replaceable top cover, whose features can be made to suitably match with the design of the house or main structure to which the said outdoor structure is associated with, is provided to embodiments in forms of hollow post and mailboxes. The method for the construction thereof comprises the steps of pre-forming and pre-casting the said main cast stone body, including said top cover for certain embodiments, separately pre-fabricating of said reinforcing structural framework, and mounting integrally and fixedly said structural framework into the pre-formed main cast stone body by a bonding means for posts and mailboxes, and an attaching means for address plaques.

1 . A pre-fabricated, reinforced cast stone outdoor structure in a form of gate, fence, garden and address posts, address plaques, mailboxes or the like, comprising: a pre-formed main cast stone body; a pre-fabricated reinforcing structural framework integrally provided to said pre-formed cast stone body; which facilitates attachment of other structural elements to the structure; and a means for mounting said structure.  
     
     
         2 . A structure according to  claim 1 , in a form of a hollow post, wherein said reinforcing structural framework is fittingly inserted, and fixedly and integrally bonded in place by a bonding means into the inner hollow section of said post.  
     
     
         3 . A structure according to  claim 1 , in forms of hollow post with a provision of a mailbox at the upper portion thereof or post type mailbox, wherein said reinforcing structural framework, being provided with a mailbox structural compartment, is fittingly inserted, and fixedly and integrally bonded in place by a bonding means into the inner hollow section of said post.  
     
     
         4 . A structure according to  claim 1 , in a form of a planar address plaque, wherein said reinforcing structural framework is integrally and fixedly attached to the peripheral edge thereof by an attaching means.  
     
     
         5 . A structure according to  claim 1  wherein said reinforcing structural framework consists of metal bars fixedly adjoined together in a pre-determined configuration.  
     
     
         6 . A structure according to  claim 1  wherein said means for mounting said structure is in a form of a mounting rod having an upper portion that is securely fitted into an integral sleeve provided to said framework, and a lower portion being pierced into the ground or fixedly secured into a concrete base or foundation.  
     
     
         7 . A structure according to  claim 1 , wherein said means for mounting said structure is in a form of a fixed and stable installation of the bases of both said structure and structural framework into a concrete foundation.  
     
     
         8 . A structure according to  claim 1 , in a form of an address post, wherein an address indicia is fixedly attached at the front side thereof.  
     
     
         9 . A structure according to  claim 6 , wherein said structure is in a form of an address post.  
     
     
         10 . A structure according to  claim 1 , wherein a connecting means is provided to said reinforcing structural framework to facilitate attachment of other structural elements to the structure.  
     
     
         11 . A structure according to  claim 1 , in forms of mailbox and address plaque, wherein said structure is capable of being seated on separate upstanding structural platform, mounted on walls or on a base foundation through supporting rods fixedly provided downwardly thereof.  
     
     
         12 . A structure according to  claim 1 , in forms of hollow post and mailbox, wherein there is provided a top cover capable of adopting a variety of designs, forms, textures, colors and shapes that suitably matches with the house or main structure design with which the said outdoor structure is associated with, said top cover being detachably fitted securely into the top opening of the pre-formed main cast stone body.  
     
     
         13 . A structure according to  claim 1  wherein said pre-formed main cast stone body is made from an admixture of calcium carbonate, resin-based adhesive and hardener, and pigments, and characterized by natural-stone-looking surface textures, roughness, crack occurrences and colors.  
     
     
         14 . A structure according to  claim 13 , wherein a strengthening material is adhesively bonded to the inner surface of the pre-formed main cast stone body.  
     
     
         15 . A method for the construction of a pre-fabricated, reinforced cast stone outdoor structure in a form of a gate, fence, garden and address posts, address plaques, mailboxes or the like comprising the steps of: 
 a. pre-forming and pre-casting a main cast stone body using a mold of pre-determined structural features;    b. drying and curing the main cast stone body in said mold;    c. removing the pre-formed main cast stone body from the mold, and preparing same for the mounting of said structural framework;    d. pre-fabricating a structural framework, including a means for mounting said structure, in accordance with the preferred dimensional, usage and design requirements and specifications suited for specific applications and embodiments of the outdoor structure; and    e. mounting integrally and fixedly said structural framework into the pre-formed main cast stone body.    
     
     
         16 . A method according to  claim 15  wherein said pre-formed main cast stone body is made from an admixture of calcium carbonate, resin-based adhesive and hardener, and pigments.  
     
     
         17 . A method according to  claim 15 , further comprising the step of bonding a strengthening material to the inner surface of the pre-formed main cast stone body before mounting said structural framework there into.  
     
     
         18 . A method according to  claim 15 , further comprising the step of pre-forming and pre-casting a top cover using a mold of pre-determined structural features.  
     
     
         19 . A method for the construction of a structure according to  claim 15 , in a form of hollow post and mailbox, wherein said structural framework is insertably, integrally and fixedly mounted into the hollow inner section of the pre-formed main cast stone body by using a bonding means in a form of fiberglass and resin mixture.  
     
     
         20 . A method for the construction of a structure according to  claim 15 , in a form of an address plaque, wherein said structural framework is integrally and fixedly mounted into the pre-formed main cast stone body by using an attaching means in a form of spikes being pierced and cast into respective apertures on the peripheral edge thereof.