Prefabricated structure for use in constructing outdoor fireplaces and the like and method of making same

Abstract

A method for off-site manufacture of prefabricated monolithic fireplaces etc comprising a plurality of concrete blocks ; the method comprising the steps of constructing a first layer of blocks, providing a steel frame and securing the same to the blocks and to a second layer of blocks constructed atop the first layer, and constructing additional layers of blocks sequentially atop the second layer each block being adhesively secured to each of its adjacent blocks.

1 . A method for the off-site manufacture of prefabricated monolithic structures comprising a plurality of blocks formed of concrete or the like and used in constructing outdoor fireplaces, grill and countertop units, bars and the like; the method comprising the steps of constructing a base layer of blocks in a desired configuration representing the perimeter of a structure, providing a rust proof structural frame of high strength metallic construction having a configuration substantially the same as that of the base layer of blocks, fixedly securing the frame in supporting relationship with interior surfaces of the base layer of blocks, sequentially constructing additional layers of blocks atop the first layer of blocks and atop each other, and affixing each of the blocks in each of the additional layers of blocks to each of its adjacent blocks by means of a high strength adhesive bonding material. 
     
     
         2 . A method as set forth in  claim 1  wherein the structural frame is also fixedly secured in supporting relationship with interior surfaces of the blocks in a second layer of blocks. 
     
     
         3 . A method as set forth in  claim 2  wherein the blocks of the first layer are somewhat wider than those of the second layer to provide a narrow substantially horizontal inwardly extending shelf defined by the top surfaces of the first layer of blocks around the perimeter of the structure, and wherein the structural frame is generally L shaped in cross sectional configuration with one leg arranged horizontally and engaging and affixed to the top surfaces of the base layer of blocks and with an integral vertical leg engaging and affixed to adjacent vertical interior surfaces of the second layer of blocks. 
     
     
         4 . A method as set forth in  claim 3  wherein the structural frame is both bolted to and secured adhesively to substantially all of the blocks in both the first and second layers of blocks. 
     
     
         5 . A method as set forth in  claim 1  wherein a high strength masonry adhesive is employed in bonding the blocks to each other. 
     
     
         6 . A method as set forth in  claim 1  wherein an opening of substantial size is provided in a front sidewall of the structure so as to enable use of the same as a fireplace. 
     
     
         7 . A method as set forth in  claim 6  wherein a second structure similar to the first and having a vertical through opening is fabricated and is placed atop the first structure to serve as a chimney. 
     
     
         8 . A method as set forth in  claim 6  wherein a horizontal rust proof metallic header is provided and installed across the top of the fireplace opening with opposite end portions secured between vertically adjacent layers of blocks. 
     
     
         9 . A method as set forth in  claim 1  wherein a substantially horizontal cooking grill of rust proof metallic construction is provided and mounted in a structure. 
     
     
         10 . A method as set forth in  claim 9  wherein a second structure similar to the first is prefabricated and positioned adjacent and in close proximity to the first structure, and wherein a large unitary countertop is provided and positioned atop both the first and second structures, an opening being provided in the countertop member to receive the grill. 
     
     
         11 . A method as set forth in  claim 1  wherein a second structure similar to the first is prefabricated and positioned adjacent and in close proximity to the first, wherein a large unitary countertop is provided and positioned atop both the first and second structures, and wherein a sink is provided in one portion of the countertop.