Trilithic and/or twin shell dome type structures and method of making same

Abstract

Trilithic Shell, Twin Shell, Multiple Shell, Curvilinear Shell as well as Free-formed Structures described herein each employ an inflatable membrane having a peripheral edge secured to an outer foundation base. An ultra-light membrane (air-form) having a network of internal cross connecting restraints is additionally secured to the inner foundation base to permit a novel and unique curvilinear surface. Pressurization then creates the backdrop upon which various urethane layers are applied which when laced with rigidifying tubes become the defining backdrop beneath which numerous cross connecting braces which when snapped into position effectively lock an inner framework to an outer framework thereby producing a self supporting truss like structure both compatible with either current dome construction and/or conventional construction practices. Shotcrete being then sprayed from the interior over said urethane coated backdrop forms highs at framework intersections and natural lows in between followed by the insertion of inflated cell tubes which span the created network of horizontal and vertical cavities are next over sprayed with urethane foam necessary to form the next natural backdrop over which two or more shotcrete/steel reinforced separate yet cross connected planes may be achieved. Such multiple yet independent rigid layers now having thousands of inner-connecting cross braces through which interior voids become natural chase-ways effectively displace 50% or more of what might otherwise be solid concrete as would be the case with all prior art thin shell structures and/or conventional stem wall construction practices. Such Free Formed curve-linear structures effectively reduce material and labor costs by as much as 50%, eliminate snap-through or oil-can buckling tendencies, enhance overall structural capacity, eliminate all height to diameter restraints, permit larger structures, facilitate floor suspension and attachment, and allow mechanical, electrical and HVAC distribution through interior chase-ways which cannot be achieved with prior art concrete thin shell single thickness structures and/or conventional stem wall, construction practices to date.

1 . A method of constructing a freeform structure comprising, the steps of constructing a light weight air-form by incorporating sewn in sleeves into which tubular reinforcements are inserted and bound to said sleeve by a resinous material thereby creating an internal network system through which restraining lines are passed so as to achieve an air-form weighing several time less then previous art air-forms while securing peripheral edge of said air-form to the outside base foundation, while additionally securing internal restraining lines to the inside base foundation so that while under pressure outward expansion of the air-form is restricted by said internal network system being placed in longitudinal as well as and latitudinal tension, thereby forming subsequent layers of insulated foam material on an inner surface of the inflated form, securing a reinforcing mesh to an inner surface of said foam layer, temporarily attaching a second horizontal rebar, attaching cross connecting braces (USIS Braces) to said reinforcing mesh, un-attaching said second horizontal rebar and locking said horizontal into the USIS Receiver Socket, followed by inner vertical rebar placements to produce a second layer of said reinforcement mesh or multiple layers necessary to create steel framed cavities or voids separating said independent multiple (two or more) layers of steel reinforcement, applying one or more layers of a cementitious material to the “outermost” inner mesh framework against the backdrop of urethane foam to a depth sufficient to embed said reinforcing mesh while building thickness at intersections where horizontal, vertical and cross bracing rebar connect, inserting un-inflated cell tubes between said created steel framed cavities, inflating said cell tubes, filling space external said cell tubes and within the created vertical channels formed into the outer shotcrete shell with a lightweight urethane or other material to displace what would normally be concrete thereby displacing weight and creating a second flat backdrop surface or multiple flat backdrop surfaces to which again one or more layers of a cementitious material are to be applied to a depth sufficient to embed said reinforcing mesh whereby achieving a multiple shell like structure.  
   
   
       2 . A method as defined in  claim 1  including the steps of securing a plurality of tension lines thereby creating an internal network system to restrain and stabilize an air-form in preparation for urethane foam layers and/or similar applications, said internal network system having 4 way intersections to which tubes are connected to create patterns through which tension lines extend and secure to base thereby strengthening the air-form necessary to apply a resin coating an underlying urethane foam application thereby resulting in a more durable foam shell requiring less interior air pressure.  
   
   
       3 . A method as defined in  claim 2  wherein each of said hanger members having an extended length over the conventional length to include a larger base portion then the conventional size hangers, while disposed against said 1 st  foam layer, to including an improved method over the conventional practices by applying a second layer of insulation being colored to assist in achieving more uniform thickness application thereby resulting in more uniform suspension of imbedded hangers within said foam material while eliminating possible air pressure penetration to the exterior to cause a distortion free exterior surface.  
   
   
       4 . A method as defined in  claim 1  wherein said air-form consisting of an internal network of restraints comprised of sewn in fabric sleeves, imbedded tubes, inserted tension lines, internal resin coating having a cooperative relation with said inflatable form so as to permit inflation to a lesser degree and without either an external restraints or internal caged ribs.  
   
   
       5 . A method as defined in  claim 1  &  4  wherein internal restraints permit the air-form to be constructed lighter and therefore inflated to a lesser pressure then conventionally practiced methods thereby eliminating the need for external restraints resulting in minimal curvature or arching between the internal framed supports, eliminating external wire restraints that require an exterior finish coating, whereby eliminating snap through buckling and/or oil can buckling as the two separated shells are constructed independently, are cross braced, become self supporting, and provide several times the conventional load bearing strength per square foot of surface area.  
   
   
       6 . A method as defined in  claim 1  wherein said cross bracing consisting of individually snapped into place Universal Snap In Standard (USIS Braces) thereby connecting an outer shell or layer with a separated inner shell or layer by way of several hundred or as many as several thousand steel bars and/or other composite material bars which together form a truss like connection between two or more spherical, half spherical, barrel, half barrel, oval, elliptical, cylindrical, flat wall and/or free formed surfaces thereby producing structural load capacities several times greater then conventional dome shell practices, hence the designation Twin Shell Structure, Multiple Shell Structure, Trilithic Dome Shell and/or free formed curve-linear structures most appropriately define this new technology.  
   
   
       7 . A method as defined in  claim 1  whereby cavities are created between shells and more specifically between USIS Braces which connect two or more shell surfaces thereby allowing un-inflated ribbons of polyethylene film or similar displacement type material to extend from one point to another point in either a vertical, horizontal and/or laterally in direction whereupon the space between such extended inflated voids through which said cross bracing extends, and once filled with a light weight insulation such as urethane or similar polymer and/or lightweight cementitious mixture resulting in the displacement of concrete weight yields a structural truss relationship between said multiple shells thereby providing structural capacities several times greater then conventional dome structure presently provide and/or hope to provide.  
   
   
       8 . A method as defined in  claim 1 ,  claim 6  and  claim 7  wherein said USIS Brace is constructed in a manner that may structurally connect an outer separated concrete shell like form to an inner separated concrete shell like form while simply snapping into position and thereby retaining both vertical and horizontal adjustability to include the capacity to receive an inserted interlocking circumferential rebar which when connected to its vertical interface forms a self supporting framework and perfectly aligned cavities through which inflated cell tubes may extend to create eventual chase-ways.  
   
   
       9 . A method as defined in  claim 1  and  claim 8  wherein inserted cell tubes constructed of polyethylene film or similar type plastic in various diameter sizes are manufactured by method of heat sealing or joining both ends whereby one end receives an inserted inflator tube that can be simply cauterized once the desired pressure is achieved, whereby such tube is used to define both the size and upward curvature of what is to become a chase-way by method of being installed between an outer shell surface of concrete and an inner shell framework of steel rebar and separated by numerous rows of cross connecting USIS Braces which traverse back and forth to connect an outer shell to what will become an inner shell once the void separating one cell tube to the next is filled with a displacement material such as urethane foam and or light weight concrete as a method to displace weight and to effectively achieve a second flat surface to which a second application of shotcrete is to be applied to render an inner shell surface.  
   
   
       10 . A method as defined in  claim 1  wherein said air-form has a generally circular periphery secured to said base, said form being configured to establish a dome shape when inflated and restrained by internal network system comprised of sewn seams, stitched sleeves, inserted tubes, which when restrained by a plurality of tension lines extending generally radially from the base foundation along the underside of the said air-form through said tubes imbedded in said sleeves to an apex coupler thereby connecting to a spring-loaded-tension device and then back down through said tubes imbedded in said sleeves along the underside of said the air-form to connect to the opposite side base foundation, and a plurality of second tensions lines extending substantially circumferentially of the dome shape generally concentric with the apex thereof, said first and second tension lines being in generally transverse overlapping relation and merely overlapping a connectivity is a function of the 4 way interconnect that receive both horizontal and vertical tube placements which comprise the internal network which underlies designated seams to form defined pattern of support.  
   
   
       11 . A method as defined in  claim 1  including the step of interconnecting said internal network as defined in  claim 10  thereby reducing the conventional air pressure thus permitting a lighter weight air-form to be used whereby permitting larger spans to be without use of an exterior restraining cable system or internal caged beam supports whereby a larger urethane shell may be applied to a lighter air-form thereby permitting a greater amount of initial rebar to be suspended until such time as the self supporting framework as defined in  claim 8  can be assembled, wherein the application of steel and shotcrete are not a function of what the air-form can support rather what the self supporting frame and the initial outer most layer of shotcrete can support until the cell tubes as defined in  claim 7  are placed thereby permitting a second-application of shotcrete to an inner shell thereby providing a structural” capacity several times greater then all other conventional methods allow while effectively eliminating any difficulty associated with snap through buckling and/or oil can buckling, while additionally diminishing the conventional and prevailing height to diameter restrains at the same time.  
   
   
       12 . A method of laser projecting not only all critical placements within a dome structure but also locating and implanting attachment points throughout interior surface, strategically placing both truss receivers from which drop rods are suspended, metal ground plates to which floors are to be quickly attached, as well as all window and door openings which must be defined before any work may commence.  
   
   
       13 . A method of constructing light weight truss frames assemblies that can be made at ground level and levitated into position once the layout work has been completed in accordance with  claim 12 .  
   
   
       14 . A method of levitating assembled truss frames as defined in  claim 1  and  13 , thereby elevating said frames to a desired floor height as defined in  claim 13  whereby DC high torque motors are used to revolve a gear reduction process comprised of a specially designed Truss Pin that is engineered to climb welded together segments of structural Acme Drop Rods extending from the ground level of the dome to a designated elevation or height at which time such truss members and their associated attachment flanges, bearings, and ground plates meet and are thereafter secured as defined in  claim 1 .  
   
   
       15 . A method of constructing a dome building comprising the steps of securing a peripheral edge of an inflatable form to a external base, securing an internal restraining network to the internal base foundation, inflating said light weight air-form under low pressure into a dome shape so that outward expansion of the form is restricted by said restraining members, applying a application of resinous material to the combined sleeves, ribs, and tubing to comprise a unified network of restraint, forming a first layer of insulation foam material on an inner surface of the inflated form, applying hanger brackets having longer and softer wire by means of laser placement device, securing a reinforcing mesh to an inner surface of said foam layer, using laser locating devices to place drop rod receiver, window and door locations, floor locations, ground plate locations, skylight locations, applying a second and third or more layers of light weight urethane or similar copolymer, placing horizontal outer rebar in a circumferential manner, placing vertical outer rebar to strategically positioned hanger brackets through use of laser spotting, placing cross connecting SIS Braces to secure outer shell to a second or third inner shell, placing internal horizontal rebar temporarily, placing internal vertical rebar to USIS Brace and Horizontal rebar using one common wire attachment, placement of cellular foam caps over internal intersections, spraying outer layers of shotcrete through all layers of rebar, placement of cell tubes within crated voids, application of urethane foam between cell tubes, applications of shotcrete to the second interior shell backdrop, of  FIG. 6   
   
   
       16 . A dome structure made in accordance with the method of  claim 15.