Metal skeleton for the reinforcement of concrete walls and floors
Abstract
A pre-engineered metal skeleton for the reinforcement of a concrete structure comprises a plurality of elongated primary beams and a plurality of interconnecting members each formed from flat sheets of metal. The interconnecting members frictionally interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without requiring supplemental fastening means. The plurality of interconnecting members have both their major axis and their minor axis oriented substantially transversely to the major axis of the elongated central main body portion of the primary beams.
Claims
exact text as granted — not AI-modifiedI claim:
1 . A metal skeleton for the reinforcement of a concrete structure to be formed therearound, the metal skeleton comprising:
a plurality of primary beams, each having a central main body portion with a major axis defining the orientation of the length of said central main body portion and a minor axis defining the orientation of the width of said central main body portion, said minor axis being transverse to said major axis, and wherein each of the plurality of primary beams is formed from a substantially flat sheet of metal material; a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, said minor axis being transverse to said major axis; wherein, the interconnecting members interlock with co-operating receiving portions formed on the primary beams to secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and with the plurality of interconnecting members having both their major axis and their minor axis oriented substantially transversely to the major axis of the central main body portion of the primary beams.
2 . The metal skeleton of claim 1 , wherein each of the interconnecting members is formed from a substantially flat sheet of metal material.
3 . The metal skeleton of claim 2 , wherein each of the plurality of primary beams and each of the interconnecting members is cut from a substantially flat sheet of metal material.
4 . The metal skeleton of claim 2 , wherein the primary beams and the plurality of interconnecting members are cut using a laser.
5 . The metal skeleton of claim 4 , wherein said central main body portion defines a plurality of apertures therein.
6 . The metal skeleton of claim 5 , wherein said primary beams each have a first side edge and a second side edge.
7 . The metal skeleton of claim 6 , wherein said first side edge and said second side edge are disposed on opposite sides of said major axis.
8 . The metal skeleton of claim 7 , wherein said first side edge and said second side edge are substantially straight.
9 . The metal skeleton of claim 8 , wherein said first side edge and said second side edge are substantially parallel one to the other.
10 . The metal skeleton of claim 9 , wherein said first side edge and said second side edge are disposed on said central main body portion.
11 . The metal skeleton of claim 10 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of at least one of said first side edge and said second side edge of each of said primary beams.
12 . The metal skeleton of claim 11 , wherein said major receiving notches each have a narrow throat portion defined by first and second facing throat edges and open to the corresponding one of the first side edge and the second side edge of said primary beams, and a wide rear portion open to said narrow throat portion.
13 . The metal skeleton of claim 11 , wherein said major receiving notches are spaced at regular intervals one from the next along the length of at least one of said first side edge and said second side edge.
14 . The metal skeleton of claim 13 , wherein said narrow throat portion has a length and a width and said wide rear portion has a length and a width, and wherein the ratio of said width to said length of said narrow throat portion is between 4:1 and 1:1.
15 . The metal skeleton of claim 14 , wherein the ratio of said width to said length of said narrow throat portion is about 2:1.
16 . The metal skeleton of claim 15 , wherein the ratio of said width to said length of said wide rear portion is between 10:1 and 5:1.
17 . The metal skeleton of claim 16 , wherein the ratio of said width to said length of said narrow throat portion is about 22:5.
18 . The metal skeleton of claim 14 , further comprising an open space disposed adjacent said first throat edge of the narrow throat portion of said major receiving notches so as to define a locking clip between said narrow throat portion and said open space, wherein said locking clip is movable between a support passing position and a support locking position, wherein in the support passing position said interconnecting members passes through said narrow throat portion and into said wide rear portion, and wherein in the support locking position said interconnecting member is precluded from passing through said narrow throat portion so as to be retained in place in said wide rear portion.
19 . The metal skeleton of claim 18 , wherein the ratio of said width to said length of said locking clip is about 5:1.
20 . The metal skeleton of claim 5 , wherein said major receiving notches are disposed along the length of both of said first side edge and said second side edge of each of said primary beams.
21 . The metal skeleton of claim 18 , wherein said major receiving notches disposed along the length of said first side edge are longitudinally aligned with the major receiving notches disposed along the length of said second side edge.
22 . The metal skeleton of claim 1 , wherein said interconnecting members are each substantially straight.
23 . The metal skeleton of claim 22 , wherein said interconnecting members each have a first side edge and a second side edge.
24 . The metal skeleton of claim 23 , wherein said first side edge and a second side edge of said interconnecting member are substantially straight.
25 . The metal skeleton of claim 22 , wherein said first side edge and said second side edge of said interconnecting member are substantially parallel one to the other.
26 . The metal skeleton of claim 23 , further comprising a plurality of minor notches disposed along the length of each said first side edge and said second side edge of said interconnecting member.
27 . The metal skeleton of claim 26 , wherein said minor notches are spaced at regular intervals one from the next along the length of said interconnecting member.
28 . The metal skeleton of claim 26 , wherein said minor notches are rectangular in shape.
29 . The metal skeleton of claim 29 , wherein said minor notches are square in shape.
30 . The metal skeleton of claim 14 , wherein each of said primary beams further comprises a first side wing portion and a second side wing portion extending transversely outwardly from said central main body portion.
31 . The metal skeleton of claim 30 , wherein said first side wing portion extends outwardly from said central main body portion at said first side edge thereof and said second side wing portion extends outwardly from said central main body portion at said second side edge thereof.
32 . The metal skeleton of claim 30 , wherein said first side wing portion and a second side wing portion are substantially transverse to said central main body portion.
33 . The metal skeleton of claim 30 , wherein said first side wing portion and a second side wing portion are substantially parallel one to the other.
34 . The metal skeleton of claim 30 , wherein said first side wing portion and said second side wing portion extend outwardly in the same direction one as the other.
35 . The metal skeleton of claim 30 , wherein said first side wing portion is disposed inwardly from the first side edge of said central main body portion and wherein said second side wing portion is disposed inwardly from the second side edge of said central main body portion.
36 . The metal skeleton of claim 35 , wherein said primary beam is formed by bending said first side wing portion into place with respect to said central main body portion and by bending said second side wing portion into place with respect to said central main body portion.
37 . The metal skeleton of claim 31 , further comprising a plurality of connector tabs interconnecting said first side wing portion and said second side wing portion to said central main body portion of said primary beam.
38 . The metal skeleton of claim 37 , further comprising at least one bendable connector finger interconnecting each of said connector tabs with said central main body portion of said primary beam.
39 . The metal skeleton of claim 38 , wherein each of said bendable connector fingers is joined to said central main body portion of said primary beam at said narrow throat portion of a corresponding one of said major receiving notches.
40 . The metal skeleton of claim 37 , wherein, when said interconnecting members is in place, a contact portion of said interconnecting member rests against the connector tab at the corresponding notch.
41 . The metal skeleton of claim 1 , wherein said plurality of primary beams are oriented substantially parallel one to the next.
42 . The metal skeleton of claim 1 , wherein the plurality of interconnecting members are oriented substantially parallel one to the next.
43 . The metal skeleton of claim 5 , further comprising a plurality of upwardly projecting hooks disposed in outwardly spaced relation from said first side edge of said central main body portion.
44 . The metal skeleton of claim 43 , wherein each of said upwardly projecting hooks is connected to the central main body portion by an extension tab.
45 . The metal skeleton of claim 44 , wherein said upwardly projecting hooks and said extension tab are in substantially the same plane as said central main body portion.
46 . The metal skeleton of claim 44 , further comprising a plurality of metal wall forms each having at least one hook-engaging portion so as to be hangable on said upwardly projecting hooks.
47 . The metal skeleton of claim 1 , wherein said central main body portion has a plurality of apertures therein.
48 . The metal skeleton of claim 47 , wherein said plurality of apertures in said central main body portion are spaced along the major axis of the primary beams.
49 . The metal skeleton of claim 48 , wherein said plurality of apertures in said central main body portion are spaced at regular intervals one from the next along the length of the primary beams.
50 . The metal skeleton of claim 1 , further comprising depth indicators extending horizontally outwardly beyond the first and second side edges of the primary beams.
51 . The metal skeleton of claim 1 , wherein said concrete structure comprises at least one of a concrete wall section and a concrete floor structure.
52 . The metal skeleton of claim 1 , further comprising weight-bearing tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, for retaining metal wall forms in weight-supported relation on said weight-bearing tabs during the forming of said concrete structure.
53 . The metal skeleton of claim 52 , wherein said weight-bearing tabs extend horizontally outwardly, as aforesaid, in parallel relation to said minor axis of said primary beams.
54 . The metal skeleton of claim 52 , wherein said weight-bearing tabs have an inner base portion and an outer frangible portion, and wherein the outer frangible portion is removable after the pouring of concrete.
55 . The metal skeleton of claim 52 , wherein said weight-bearing tabs extend through vertically oriented co-operating slots in the metal wall forms to thereby support the metal wall forms during pouring of concrete.
56 . The metal skeleton of claim 54 , wherein said inner base portion and said outer frangible portion are joined to each other at a pair of opposed “V”-notches.
57 . The metal skeleton of claim 54 , wherein said outer frangible portion has at least one wedge-receiving aperture therein that receives a securing wedge therein to hold the metal wall forms in place during the pouring and curing of concrete.
58 . The metal skeleton of claim 57 , wherein said securing wedge is removable from said at least one wedge-receiving aperture subsequent to the pouring and curing of concrete.
59 . The metal skeleton of claim 55 , further comprising inwardly oriented projections on the metal wall forms for engaging with the poured concrete to retain the metal wall forms in place after curing of said poured concrete.
60 . The metal skeleton of claim 1 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of said primary beams.
61 . The metal skeleton of claim 60 , wherein said plurality of major receiving notches comprise vertically oriented slots.
62 . The metal skeleton of claim 1 , further comprising bendable tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, wherein said bendable tabs are bendable between an initial position and a securing position whereat the interconnecting members are secured in place.
63 . The metal skeleton of claim 62 , wherein said interconnecting members are inter-connected together to form a lattice positioned adjacent one or both of said first side edge and said second side edge.
64 . The metal skeleton of claim 63 , wherein said bendable tabs extend through co-operating tab-receiving apertures formed in said interconnecting members where the interconnecting members intersect one another.
65 . The metal skeleton of claim 4 , wherein said primary beams and said interconnecting members are substantially pre-cut so as to be retained in place by frangible connection points left uncut in substantially flat sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said flat sheets of metal material after shipping to an assembly site.
66 . The metal skeleton of claim 65 , wherein said remainder of said flat sheets of metal material include instructions related to the assembly of said metal skeleton laser etched thereon.
67 . A metal skeleton for the reinforcement of a concrete structure to be formed therearound, the metal skeleton comprising:
a plurality of primary beams, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, and wherein said minor axis is transverse to said major axis; a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, said minor axis being transverse to said major axis; a plurality of major receiving notches disposed along the length of each of said primary beams, wherein said major receiving notches each have a narrow throat portion and a wide rear portion open to the narrow throat portion; wherein, the interconnecting members interlock with said major receiving notches formed on the primary beams to secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and the plurality of interconnecting members each have both their major axis and their minor axis oriented substantially transversely to the major axis of the primary beams.
68 . The metal skeleton of claim 67 , wherein each said narrow throat portion is defined by first and second facing throat edges and each said wide rear portion has ends.
69 . The metal skeleton of claim 67 , wherein said major receiving notches are spaced at regular intervals one from the next along the length of at least one of said first side edge and said second side edge.
70 . The metal skeleton of claim 67 , wherein said narrow throat portion has a length and a width and said wide rear portion has a length and a width, and wherein the ratio of said width to said length of said narrow throat portion is between 4:1 and 1:1.
71 . The metal skeleton of claim 70 , wherein the ratio of said width to said length of said narrow throat portion is about 2:1.
72 . The metal skeleton of claim 71 , wherein the ratio of said width to said length of said wide rear portion is between 10:1 and 5:1.
73 . The metal skeleton of claim 72 , wherein the ratio of said width to said length of said narrow throat portion is about 22:5.
74 . The metal skeleton of claim 68 , further comprising an open space disposed adjacent said first throat edge of the narrow throat portion of said major receiving notches so as to define a locking clip between said narrow throat portion and said open space, wherein said locking clip is movable between a support passing position and a support locking position, wherein in the support passing position said interconnecting members pass through said narrow throat portion and into said wide rear portion, and wherein in the support locking position said interconnecting member is precluded from passing through said narrow throat portion and is thereby retained in place in said wide rear portion.
75 . The metal skeleton of claim 74 , wherein the ratio of said width to said length of said locking clip is about 5:1.
76 . The metal skeleton of claim 67 , wherein said primary beams each have a first side edge and a second side edge on opposite sides of said major axis, and wherein the plurality of major receiving notches is disposed along the length of at least one of said first side edge and said second side edge of said primary beams.
77 . The metal skeleton of claim 76 , wherein said narrow throat portion is open to the corresponding one of the first side edge or the second side edge.
78 . The metal skeleton of claim 77 , wherein said major receiving notches are disposed along the length of both of said first side edge and said second side edge of each of said primary beams.
79 . The metal skeleton of claim 76 , wherein said major receiving notches disposed along the length of said first side edge are longitudinally aligned with the major receiving notches disposed along the length of said second side edge.
80 . The metal skeleton of claim 67 , wherein each of the interconnecting members is formed from a substantially flat sheet of metal material.
81 . The metal skeleton of claim 67 , wherein each of the plurality of primary beams and each of the interconnecting members is cut from a substantially flat sheet of metal material.
82 . The metal skeleton of claim 67 , wherein the primary beams and the plurality of interconnecting members are cut using a laser.
83 . The metal skeleton of claim 67 , wherein said central main body portion defines a plurality of apertures therein.
84 . The metal skeleton of claim 67 , wherein said primary beams each have a first side edge and a second side edge.
85 . The metal skeleton of claim 84 , wherein said first side edge and said second side edge are outwardly disposed.
86 . The metal skeleton of claim 85 , wherein said first side edge and said second side edge are substantially straight.
87 . The metal skeleton of claim 86 , wherein said first side edge and said second side edge are substantially parallel one to the other.
88 . The metal skeleton of claim 87 , wherein said first side edge and said second side edge are disposed on said central main body portion.
89 . The metal skeleton of claim 67 , wherein said interconnecting members are each substantially straight.
90 . The metal skeleton of claim 89 , wherein said interconnecting members each have a first side edge and a second side edge.
91 . The metal skeleton of claim 90 , wherein said first side edge and a second side edge of said interconnecting member are substantially straight.
92 . The metal skeleton of claim 89 , wherein said first side edge and said second side edge of said interconnecting member are substantially parallel one to the other.
93 . The metal skeleton of claim 90 , further comprising a plurality of minor notches disposed along the length of each said first side edge and said second side edge of said interconnecting member.
94 . The metal skeleton of claim 93 , wherein said minor notches are spaced at regular intervals one from the next along the length of said interconnecting member.
95 . The metal skeleton of claim 93 , wherein said minor notches are rectangular in shape.
96 . The metal skeleton of claim 95 , wherein said minor notches are square in shape.
97 . The metal skeleton of claim 67 , wherein each of said primary beams further comprises a first side wing portion and a second side wing portion extending outwardly from said central main body portion.
98 . The metal skeleton of claim 97 , wherein said first side wing portion extends outwardly from said central main body portion at said first side edge thereof and said second side wing portion extends outwardly from said central main body portion at said second side edge thereof.
99 . The metal skeleton of claim 97 , wherein said first side wing portion and a second side wing portion are substantially transverse to said central main body portion.
100 . The metal skeleton of claim 97 , wherein said first side wing portion and a second side wing portion are substantially parallel one to the other.
101 . The metal skeleton of claim 97 , wherein said first side wing portion and a second side wing portion extend outwardly in same direction one as the other.
102 . The metal skeleton of claim 97 , wherein said first side wing portion is disposed inwardly from the first side edge of said central main body portion and wherein said second side wing portion is disposed inwardly from the second side edge of said central main body portion.
103 . The metal skeleton of claim 102 , wherein said primary beam is formed by bending said first side wing portion into place with respect to said central main body portion and by bending said second side wing portion into place with respect to said central main body portion.
104 . The metal skeleton of claim 98 , further comprising a plurality of connector tabs interconnecting said first side wing portion and said second side wing portion to said central main body portion of said primary beam.
105 . The metal skeleton of claim 104 , further comprising at least one bendable connector finger interconnecting each of said connector tabs with said central main body portion of said primary beam.
106 . The metal skeleton of claim 105 , wherein each of said bendable connector fingers is joined to said central main body portion of said primary beam at said narrow throat portion of a corresponding one of said major receiving notches.
107 . The metal skeleton of claim 98 , wherein, when said interconnecting members is in place, a contact portion of said interconnecting member rests against the connector tab at the corresponding notch.
108 . The metal skeleton of claim 67 , wherein said plurality of primary beams are oriented substantially parallel one to the next.
109 . The metal skeleton of claim 67 , wherein the plurality of interconnecting members are oriented substantially parallel one to the next.
110 . The metal skeleton of claim 83 , further comprising a plurality of upwardly projecting hooks disposed in outwardly spaced relation from said first side edge of said central main body portion.
111 . The metal skeleton of claim 110 , wherein each of said upwardly projecting hooks is connected to the central main body portion by an extension tab.
112 . The metal skeleton of claim 111 , wherein said upwardly projecting hooks and said extension tab are in substantially the same plane as said central main body portion.
113 . The metal skeleton of claim 111 , further comprising a plurality of metal wall forms each having at least one hook-engaging portion so as to be hangable on said upwardly projecting hooks.
114 . The metal skeleton of claim 67 , wherein said central main body portion has a plurality of apertures therein.
115 . The metal skeleton of claim 114 , wherein said plurality of apertures in said central main body portion are spaced along the major axis of the primary beams.
116 . The metal skeleton of claim 115 , wherein said plurality of apertures in said central main body portion are spaced at regular intervals one from the next along said major axis.
117 . The metal skeleton of claim 67 , further comprising depth indicators extending horizontally outwardly beyond the first and second side edges of the primary beams.
118 . The metal skeleton of claim 67 , wherein said concrete structure comprises at least one of a concrete wall section and a concrete floor structure.
119 . The metal skeleton of claim 67 , further comprising weight-bearing tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, for retaining wall forms in weight-supported relation on said weight-bearing tabs during the forming of said concrete structure.
120 . The metal skeleton of claim 119 , wherein said wall forms comprise metal wall forms.
121 . The metal skeleton of claim 119 , wherein said weight-bearing tabs extend horizontally outwardly, as aforesaid, in parallel relation to said minor axis of said primary beams.
122 . The metal skeleton of claim 119 , wherein said weight-bearing tabs have an inner base portion and an outer frangible portion, and wherein the outer frangible portion is removable after the pouring of concrete.
123 . The metal skeleton of claim 119 , wherein said weight-bearing tabs extend through vertically oriented co-operating slots in the metal wall forms to thereby support the metal wall forms during pouring of concrete.
124 . The metal skeleton of claim 123 , wherein said inner base portion and said outer frangible portion are joined to each other at a pair of opposed “V”-notches.
125 . The metal skeleton of claim 123 , wherein said outer frangible portion has at least one wedge-receiving aperture therein that receives a securing wedge therein to hold the metal wall forms in place during the pouring and curing of concrete.
126 . The metal skeleton of claim 125 , wherein said securing wedge is removable from said at least one wedge-receiving aperture subsequent to the pouring and curing of concrete.
127 . The metal skeleton of claim 123 , further comprising inwardly oriented projections on the metal wall forms for engaging with the poured concrete to retain the metal wall forms in place after curing of said poured concrete.
128 . The metal skeleton of claim 67 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of said primary beams.
129 . The metal skeleton of claim 128 , wherein said plurality of major receiving notches comprise vertically oriented slots.
130 . The metal skeleton of claim 67 , further comprising bendable tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, wherein said bendable tabs are bendable between an initial position and a securing position whereat the interconnecting members are secured in place.
131 . The metal skeleton of claim 130 , wherein said interconnecting members are inter-connected together to form a lattice positioned adjacent one or both of said first side edge and said second side edge.
132 . The metal skeleton of claim 131 , wherein said bendable tabs extend through co-operating tab-receiving apertures in said interconnecting members where the interconnecting members intersect one another.
133 . The metal skeleton of claim 67 , wherein said primary beams and said interconnecting members are substantially pre-cut and are retained in place by frangible connection points left uncut in substantially flat sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said flat sheets of metal material after shipping to an assembly site.
134 . The metal skeleton of claim 133 , wherein said remainder of said flat sheets of metal material include instructions related to the assembly of said metal skeleton laser etched thereon.
135 . A metal skeleton for the reinforcement of a concrete structure to be formed therearound, the metal skeleton comprising:
a plurality of primary beams, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, said minor axis being transverse to said major axis; a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, said minor axis being transverse to said major axis; a plurality of major receiving notches disposed along the length of each of said primary beams, wherein said major receiving notches each have a narrow throat portion defined by first and second facing throat edges; said receiving notches each further comprising an open space disposed adjacent said first throat edge of the narrow throat portion so as to define a locking clip between said narrow throat portion and said open space, with said locking clip being movable between a support passing position and a support locking position, such that, in the support passing position, said interconnecting members passes through said narrow throat portion and into said wide rear portion, and wherein, in the support locking position, said interconnecting member is precluded from passing through said narrow throat portion so as to be retained in place in said wide rear portion; and such that the interconnecting members interlock by said locking clips with said major receiving notches formed on the primary beams, to secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and the plurality of interconnecting members each have both their major axis and their minor axis oriented substantially transversely to the major axis of the primary beams.
136 . The metal skeleton of claim 135 , wherein the ratio of said width to said length of said locking clip is about 5:1.
137 . The metal skeleton of claim 135 , wherein each said narrow throat portion is defined by first and second facing throat edges and each said wide rear portion has ends.
138 . The metal skeleton of claim 135 , wherein said major receiving notches are spaced at regular intervals one from the next along the length of at least one of said first side edge and said second side edge.
139 . The metal skeleton of claim 135 , wherein said narrow throat portion has a length and a width and said wide rear portion has a length and a width, and wherein the ratio of said width to said length of said narrow throat portion is between 4:1 and 1:1.
140 . The metal skeleton of claim 139 , wherein the ratio of said width to said length of said narrow throat portion is about 2:1.
141 . The metal skeleton of claim 140 , wherein the ratio of said width to said length of said wide rear portion is between 10:1 and 5:1.
142 . The metal skeleton of claim 141 , wherein the ratio of said width to said length of said narrow throat portion is about 22:5.
143 . The metal skeleton of claim 135 , wherein said primary beams each have a first side edge and a second side edge on opposite sides of said major axis, and wherein the plurality of major receiving notches is disposed along the length of at least one of said first side edge and said second side edge of said primary beams.
144 . The metal skeleton of claim 143 , wherein said narrow throat portion is open to the corresponding one of the first side edge or the second side edge.
145 . The metal skeleton of claim 144 , wherein said major receiving notches are disposed along the length of both of said first side edge and said second side edge of each of said primary beams.
146 . The metal skeleton of claim 143 , wherein said major receiving notches disposed along the length of said first side edge are longitudinally aligned with the major receiving notches disposed along the length of said second side edge.
147 . The metal skeleton of claim 135 , wherein each of the interconnecting members is formed from a substantially flat sheet of metal material.
148 . The metal skeleton of claim 147 , wherein each of the plurality of primary beams and each of the interconnecting members is cut from a substantially flat sheet of metal material.
149 . The metal skeleton of claim 148 , wherein the primary beams and the plurality of interconnecting members are cut using a laser.
150 . The metal skeleton of claim 135 , wherein said central main body portion defines a plurality of apertures therein.
151 . The metal skeleton of claim 135 , wherein said primary beams each have a first side edge and a second side edge.
152 . The metal skeleton of claim 151 , wherein said first side edge and said second side edge are outwardly disposed.
153 . The metal skeleton of claim 152 , wherein said first side edge and said second side edge are substantially straight.
154 . The metal skeleton of claim 153 , wherein said first side edge and said second side edge are substantially parallel one to the other.
155 . The metal skeleton of claim 154 , wherein said first side edge and said second side edge are disposed on said central main body portion.
156 . The metal skeleton of claim 135 , wherein said interconnecting members are each substantially straight.
157 . The metal skeleton of claim 156 , wherein said interconnecting members each have a first side edge and a second side edge.
158 . The metal skeleton of claim 157 , wherein said first side edge and a second side edge of said interconnecting member are substantially straight.
159 . The metal skeleton of claim 158 , wherein said first side edge and said second side edge of said interconnecting member are substantially parallel one to the other.
160 . The metal skeleton of claim 159 , further comprising a plurality of minor notches disposed along the length of each said first side edge and said second side edge of said interconnecting member.
161 . The metal skeleton of claim 160 , wherein said minor notches are spaced at regular intervals one from the next along the length of said interconnecting member.
162 . The metal skeleton of claim 160 , wherein said minor notches are rectangular in shape.
163 . The metal skeleton of claim 162 , wherein said minor notches are square in shape.
164 . The metal skeleton of claim 135 , wherein each of said primary beams further comprises a first side wing portion and a second side wing portion extending outwardly from said central main body portion.
165 . The metal skeleton of claim 164 , wherein said first side wing portion extends outwardly from said central main body portion at said first side edge thereof and said second side wing portion extends outwardly from said central main body portion at said second side edge thereof.
166 . The metal skeleton of claim 164 , wherein said first side wing portion and a second side wing portion are substantially transverse to said central main body portion.
167 . The metal skeleton of claim 164 , wherein said first side wing portion and a second side wing portion are substantially parallel one to the other.
168 . The metal skeleton of claim 164 , wherein said first side wing portion and a second side wing portion extend outwardly in the same direction one as the other.
169 . The metal skeleton of claim 164 , wherein said first side wing portion is disposed inwardly from the first side edge of said central main body portion and wherein said second side wing portion is disposed inwardly from the second side edge of said central main body portion.
170 . The metal skeleton of claim 169 , wherein said primary beam is formed by bending said first side wing portion into place with respect to said central main body portion and by bending said second side wing portion into place with respect to said central main body portion.
171 . The metal skeleton of claim 165 , further comprising a plurality of connector tabs interconnecting said first side wing portion and said second side wing portion to said central main body portion of said primary beam.
172 . The metal skeleton of claim 171 , further comprising at least one bendable connector finger interconnecting each of said connector tabs with said central main body portion of said primary beam.
173 . The metal skeleton of claim 172 , wherein each of said bendable connector fingers is joined to said central main body portion of said primary beam at said narrow throat portion of a corresponding one of said major receiving notches.
174 . The metal skeleton of claim 165 , wherein, when said interconnecting members is in place, a contact portion of said interconnecting member rests against the connector tab at the corresponding notch.
175 . The metal skeleton of claim 135 , wherein said plurality of primary beams are oriented substantially parallel one to the next.
176 . The metal skeleton of claim 135 , wherein the plurality of interconnecting members are oriented substantially parallel one to the next.
177 . The metal skeleton of claim 150 , further comprising a plurality of upwardly projecting hooks disposed in outwardly spaced relation from said first side edge of said central main body portion.
178 . The metal skeleton of claim 177 , wherein each of said upwardly projecting hooks is connected to the central main body portion by an extension tab.
179 . The metal skeleton of claim 178 , wherein said upwardly projecting hooks and said extension tab are in substantially the same plane as said central main body portion.
180 . The metal skeleton of claim 178 , further comprising a plurality of metal wall forms each having at least one hook-engaging portion so as to be hangable on said upwardly projecting hooks.
181 . The metal skeleton of claim 135 , wherein said central main body portion has a plurality of apertures therein.
182 . The metal skeleton of claim 181 , wherein said plurality of apertures in said central main body portion are spaced along the major axis of the primary beams.
183 . The metal skeleton of claim 182 , wherein said plurality of apertures in said central main body portion are spaced at regular intervals one from the next along the length of the primary beams.
184 . The metal skeleton of claim 135 , further comprising depth indicators extending horizontally outwardly beyond the first and second side edges of the primary beams.
185 . The metal skeleton of claim 135 , wherein said concrete structure comprises at least one of a concrete wall section and a concrete floor structure.
186 . The metal skeleton of claim 135 , further comprising weight-bearing tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, for retaining wall forms in weight-supported relation on said weight-bearing tabs during the forming of said concrete structure.
187 . The metal skeleton of claim 186 , wherein said wall forms comprise metal wall forms.
188 . The metal skeleton of claim 187 , wherein said weight-bearing tabs extend horizontally outwardly, as aforesaid, in parallel relation to said minor axis of said primary beams.
189 . The metal skeleton of claim 187 , wherein said weight-bearing tabs have an inner base portion and an outer frangible portion, and wherein the outer frangible portion is removable after the pouring of concrete.
190 . The metal skeleton of claim 187 , wherein said weight-bearing tabs extend through vertically oriented co-operating slots in the metal wall forms to thereby support the metal wall forms during pouring of concrete.
191 . The metal skeleton of claim 189 , wherein said inner base portion and said outer frangible portion are joined to each other at a pair of opposed “V”-notches.
192 . The metal skeleton of claim 189 , wherein said outer frangible portion has at least one wedge-receiving aperture therein that receives a securing wedge therein to hold the metal wall forms in place during the pouring and curing of concrete.
193 . The metal skeleton of claim 192 , wherein said securing wedge is removable from said at least one wedge-receiving aperture subsequent to the pouring and curing of concrete.
194 . The metal skeleton of claim 190 , further comprising inwardly oriented projections on the metal wall forms for engaging with the poured concrete to retain the metal wall forms in place after curing of said poured concrete.
195 . The metal skeleton of claim 135 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of said primary beams.
196 . The metal skeleton of claim 195 , wherein said plurality of major receiving notches comprise vertically oriented slots.
197 . The metal skeleton of claim 135 , further comprising bendable tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, wherein said bendable tabs are bendable between an initial position and a securing position whereat the interconnecting members are secured in place.
198 . The metal skeleton of claim 197 , wherein said interconnecting members are inter-connected together to form a lattice positioned adjacent one or both of said first side edge and said second side edge.
199 . The metal skeleton of claim 198 , wherein said bendable tabs extend through co-operating tab-receiving apertures in said interconnecting members where the interconnecting members intersect one another.
200 . The metal skeleton of claim 135 , wherein said primary beams and said interconnecting members are substantially pre-cut and so as to be retained in place by frangible connection points left uncut in substantially flat sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said flat sheets of metal material after shipping to an assembly site.
201 . The metal skeleton of claim 200 , wherein said remainder of said flat sheets of metal material include instructions related to the assembly of said metal skeleton laser etched thereon.
202 . A metal skeleton for the reinforcement of a concrete structure to be formed therearound, said concrete structure having a thickness defined between first and second opposed surfaces positioned on opposite sides of a medial plane of said metal skeleton, the metal skeleton comprising:
a plurality of primary beams, each having a central main body portion with a major axis defining the orientation of the length of said central main body portion and a minor axis defining the orientation of the width of said central main body portion, said minor axis being transverse to said major axis, and wherein each of the plurality of primary beams is formed from a substantially flat sheet of metal material; a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, said minor axis being transverse to said major axis; wherein, the interconnecting members interlock with co-operating receiving portions formed on the primary beams to secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and with the plurality of interconnecting members having both their major axis and their minor axis oriented substantially transverse to the major axis of the primary beams, and such that the primary beams are oriented with their major axis arranged substantially parallel one to the next and with their minor axis arranged substantially transverse to said medial plane, and with their widths extending between said first and second opposed surfaces.
203 . The metal skeleton of claim 202 , wherein each of the interconnecting members is formed from a substantially flat sheet of metal material.
204 . The metal skeleton of claim 203 , wherein each of the plurality of primary beams and each of the interconnecting members is cut from a substantially flat sheet of metal material.
205 . The metal skeleton of claim 203 , wherein the primary beams and the plurality of interconnecting members are cut using a laser.
206 . The metal skeleton of claim 202 , wherein said central main body portion defines a plurality of apertures therein.
207 . The metal skeleton of claim 202 , wherein said primary beams each have a first side edge and a second side edge.
208 . The metal skeleton of claim 207 , wherein said first side edge and said second side edge are disposed on opposite sides of said major axis.
209 . The metal skeleton of claim 208 , wherein said first side edge and said second side edge are substantially straight.
210 . The metal skeleton of claim 209 , wherein said first side edge and said second side edge are substantially parallel one to the other.
211 . The metal skeleton of claim 210 , wherein said first side edge and said second side edge are disposed on said central main body portion.
212 . The metal skeleton of claim 211 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of at least one of said first side edge and said second side edge of each of said primary beams.
213 . The metal skeleton of claim 212 , wherein said major receiving notches each have a narrow throat portion defined by first and second facing throat edges and open to the corresponding one of the first side edge and the second side edge of said primary beams, and a wide rear portion open to said narrow throat portion.
214 . The metal skeleton of claim 212 , wherein said major receiving notches are spaced at regular intervals one from the next along the length of at least one of said first side edge and said second side edge.
215 . The metal skeleton of claim 214 , wherein said narrow throat portion has a length and a width and said wide rear portion has a length and a width, and wherein the ratio of said width to said length of said narrow throat portion is between 4:1 and 1:1.
216 . The metal skeleton of claim 215 , wherein the ratio of said width to said length of said narrow throat portion is about 2:1.
217 . The metal skeleton of claim 216 , wherein the ratio of said width to said length of said wide rear portion is between 10:1 and 5:1.
218 . The metal skeleton of claim 217 , wherein the ratio of said width to said length of said narrow throat portion is about 22:5.
219 . The metal skeleton of claim 215 , further comprising an open space disposed adjacent said first throat edge of the narrow throat portion of said major receiving notches so as to define a locking clip between said narrow throat portion and said open space, wherein said locking clip is movable between a support passing position and a support locking position, wherein in the support passing position said interconnecting members passes through said narrow throat portion and into said wide rear portion, and wherein in the support locking position said interconnecting member is precluded from passing through said narrow throat portion so as to be retained in place in said wide rear portion.
220 . The metal skeleton of claim 219 , wherein the ratio of said width to said length of said locking clip is about 5:1.
221 . The metal skeleton of claim 206 , wherein said major receiving notches are disposed along the length of both of said first side edge and said second side edge of each of said primary beams.
222 . The metal skeleton of claim 219 , wherein said major receiving notches disposed along the length of said first side edge are longitudinally aligned with the major receiving notches disposed along the length of said second side edge.
223 . The metal skeleton of claim 202 , wherein said interconnecting members are each substantially straight.
224 . The metal skeleton of claim 223 , wherein said interconnecting members each have a first side edge and a second side edge.
225 . The metal skeleton of claim 224 , wherein said first side edge and a second side edge of said interconnecting member are substantially straight.
226 . The metal skeleton of claim 223 , wherein said first side edge and said second side edge of said interconnecting member are substantially parallel one to the other.
227 . The metal skeleton of claim 224 , further comprising a plurality of minor notches disposed along the length of each said first side edge and said second side edge of said interconnecting member.
228 . The metal skeleton of claim 227 , wherein said minor notches are spaced at regular intervals one from the next along the length of said interconnecting member.
229 . The metal skeleton of claim 227 , wherein said minor notches are rectangular in shape.
230 . The metal skeleton of claim 229 , wherein said minor notches are square in shape.
231 . The metal skeleton of claim 215 , wherein each of said primary beams further comprises a first side wing portion and a second side wing portion extending transversely outwardly from said central main body portion.
232 . The metal skeleton of claim 231 , wherein said first side wing portion extends outwardly from said central main body portion at said first side edge thereof and said second side wing portion extends outwardly from said central main body portion at said second side edge thereof.
233 . The metal skeleton of claim 231 , wherein said first side wing portion and a second side wing portion are substantially transverse to said central main body portion.
234 . The metal skeleton of claim 231 , wherein said first side wing portion and a second side wing portion are substantially parallel one to the other.
235 . The metal skeleton of claim 231 , wherein said first side wing portion and said second side wing portion extend outwardly in the same direction one as the other.
236 . The metal skeleton of claim 231 , wherein said first side wing portion is disposed inwardly from the first side edge of said central main body portion and wherein said second side wing portion is disposed inwardly from the second side edge of said central main body portion.
237 . The metal skeleton of claim 236 , wherein said primary beam is formed by bending said first side wing portion into place with respect to said central main body portion and by bending said second side wing portion into place with respect to said central main body portion.
238 . The metal skeleton of claim 232 , further comprising a plurality of connector tabs interconnecting said first side wing portion and said second side wing portion to said central main body portion of said primary beam.
239 . The metal skeleton of claim 238 , further comprising at least one bendable connector finger interconnecting each of said connector tabs with said central main body portion of said primary beam.
240 . The metal skeleton of claim 239 , wherein each of said bendable connector fingers is joined to said central main body portion of said primary beam at said narrow throat portion of a corresponding one of said major receiving notches.
241 . The metal skeleton of claim 238 , wherein, when said interconnecting members is in place, a contact portion of said interconnecting member rests against the connector tab at the corresponding notch.
242 . The metal skeleton of claim 202 , wherein said plurality of primary beams are oriented substantially parallel one to the next.
243 . The metal skeleton of claim 202 , wherein the plurality of interconnecting members are oriented substantially parallel one to the next.
244 . The metal skeleton of claim 206 , further comprising a plurality of upwardly projecting hooks disposed in outwardly spaced relation from said first side edge of said central main body portion.
245 . The metal skeleton of claim 244 , wherein each of said upwardly projecting hooks is connected to the central main body portion by an extension tab.
246 . The metal skeleton of claim 245 , wherein said upwardly projecting hooks and said extension tab are in substantially the same plane as said central main body portion.
247 . The metal skeleton of claim 245 , further comprising a plurality of wall forms each having at least one hook-engaging portion so as to be hangable on said upwardly projecting hooks.
248 . The metal skeleton of claim 247 , wherein said wall forms comprise metal wall forms.
249 . The metal skeleton of claim 202 , wherein said central main body portion has a plurality of apertures therein.
250 . The metal skeleton of claim 249 , wherein said plurality of apertures in said central main body portion are spaced along the major axis of the primary beams.
251 . The metal skeleton of claim 250 , wherein said plurality of apertures in said central main body portion are spaced at regular intervals one from the next along the length of the primary beams.
252 . The metal skeleton of claim 202 , further comprising depth indicators extending horizontally outwardly beyond the first and second side edges of the primary beams.
253 . The metal skeleton of claim 202 , wherein said concrete structure comprises at least one of a concrete wall section and a concrete floor structure.
254 . The metal skeleton of claim 202 , further comprising weight-bearing tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, for retaining metal wall forms in weight-supported relation on said weight-bearing tabs during the forming of said concrete structure.
255 . The metal skeleton of claim 254 , wherein said weight-bearing tabs extend horizontally outwardly, as aforesaid, in parallel relation to said minor axis of said primary beams.
256 . The metal skeleton of claim 254 , wherein said weight-bearing tabs have an inner base portion and an outer frangible portion, and wherein the outer frangible portion is removable after the pouring of concrete.
257 . The metal skeleton of claim 254 , wherein said weight-bearing tabs extend through vertically oriented co-operating slots in the metal wall forms to thereby support the metal wall forms during pouring of concrete.
258 . The metal skeleton of claim 256 , wherein said inner base portion and said outer frangible portion are joined to each other at a pair of opposed “V”-notches.
259 . The metal skeleton of claim 256 , wherein said outer frangible portion has at least one wedge-receiving aperture therein that receives a securing wedge therein to hold the metal wall forms in place during the pouring and curing of concrete.
260 . The metal skeleton of claim 259 , wherein said securing wedge is removable from said at least one wedge-receiving aperture subsequent to the pouring and curing of concrete.
261 . The metal skeleton of claim 257 , further comprising inwardly oriented projections on the metal wall forms for engaging with the poured concrete to retain the metal wall forms in place after curing of said poured concrete.
262 . The metal skeleton of claim 202 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of said primary beams.
263 . The metal skeleton of claim 262 , wherein said plurality of major receiving notches comprise vertically oriented slots.
264 . The metal skeleton of claim 202 , further comprising bendable tabs extending horizontally outwardly beyond said first side edges and said second side edges of the primary beams, wherein said bendable tabs are bendable between an initial position and a securing position whereat the interconnecting members are secured in place.
265 . The metal skeleton of claim 264 , wherein said interconnecting members are inter-connected together to form a lattice positioned adjacent one or both of said first side edge and said second side edge.
266 . The metal skeleton of claim 265 , wherein said bendable tabs extend through co-operating tab-receiving apertures formed in said interconnecting members where the interconnecting members intersect one another.
267 . The metal skeleton of claim 205 , wherein said primary beams and said interconnecting members are substantially pre-cut so as to be retained in place by frangible connection points left uncut in substantially flat sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said flat sheets of metal material after shipping to an assembly site.
268 . The metal skeleton of claim 266 , wherein said remainder of one or more of said flat sheets of metal material have assembly instructions for at least a portion of said metal skeleton laser etched thereon.
269 . A kit for assembling a metal skeleton for the reinforcement of a concrete structure to be formed therearound, the kit comprising:
a plurality of primary beams, each having a central main body portion with a major axis defining the orientation of the length of said central main body portion and a minor axis defining the orientation of the width of said central main body portion, said minor axis being transverse to said major axis, and wherein each of the plurality of primary beams is formed from a substantially flat sheet of metal material; a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, said minor axis being transverse to said major axis; wherein, the interconnecting members are dimensioned and otherwise adapted to interlock with co-operating receiving portions integrally formed on the primary beams to secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and with the plurality of interconnecting members each having both their major axis and their minor axis oriented substantially transversely to the major axis of the central main body portion of the primary beams upon assembly of said metal skeleton.
270 . The kit of claim 269 , wherein one or more of each of the primary beams or the interconnecting members is formed by cutting each from substantially flat sheets of metal material.
271 . The kit of claim 269 , additionally comprising a container into which said primary beams and said interconnecting members may be placed subsequent to said primary beams and said interconnecting members being formed from said substantially flat sheets of metal material, for shipment and/or storage prior to assembly of said metal skeleton.
272 . The kit of claim 271 , wherein said container comprises a container into which said substantially flat formed sheets of metal material having said primary beams and said interconnecting members formed therein may be placed subsequent to said primary beams and said interconnecting members being formed in said substantially flat formed sheets of metal material, for shipment and/or storage.
273 . The kit of claim 271 , wherein said container comprises a shipping container.
274 . The kit of claim 273 , wherein said shipping container comprises a lockable shipping container.
275 . The kit of claim 269 , wherein said primary beams and said interconnecting members are substantially pre-cut from one or more substantially flat sheets of metal material so as to be retained in place by frangible connection points left uncut in said substantially flat formed sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said after shipping to an assembly site.
276 . The kit of claim 275 , additionally comprising a container into which said primary beams and said interconnecting members may be placed subsequent to said primary beams and said interconnecting members being formed from said substantially flat sheets of metal material, for shipment and/or storage.
277 . The kit of claim 276 , wherein said container comprises a container into which said substantially flat formed sheets of metal material having said primary beams and said interconnecting members formed therein may be placed subsequent to said primary beams and said interconnecting members being formed in said substantially flat formed sheets of metal material, for shipment and/or storage.
278 . The kit of claim 276 , wherein said container comprises a shipping container.
279 . The kit of claim 278 , wherein said shipping container comprises a lockable shipping container.
280 . The kit of claim 269 , wherein said one or more of said substantially flat formed sheets of metal material have assembly instructions for at least a portion of said metal skeleton laser etched thereon.
281 . The kit of claim 274 , wherein said assembly instructions are laser etched on said remainder of one or more of said substantially flat formed sheets of metal material.
282 . The kit of claim 269 , wherein said receiving portions comprise a plurality of major receiving notches disposed along the length of at least one of said first side edge and said second side edge of each of said primary beams.
283 . The kit of claim 282 , wherein said major receiving notches each have a narrow throat portion defined by first and second facing throat edges and open to the corresponding one of the first side edge and the second side edge of said primary beams, and a wide rear portion open to said narrow throat portion.
284 . The kit of claim 282 , wherein said major receiving notches are spaced at regular intervals one from the next along the length of at least one of said first side edge and said second side edge.
285 . The kit of claim 284 , wherein said narrow throat portion has a length and a width and said wide rear portion has a length and a width, and wherein the ratio of said width to said length of said narrow throat portion is between 4:1 and 1:1.
286 . The kit of claim 285 , wherein the ratio of said width to said length of said narrow throat portion is about 2:1.
287 . The kit of claim 286 , wherein the ratio of said width to said length of said wide rear portion is between 10:1 and 5:1.
288 . The kit of claim 287 , wherein the ratio of said width to said length of said narrow throat portion is about 22:5.
289 . The kit of claim 288 , further comprising an open space disposed adjacent said first throat edge of the narrow throat portion of said major receiving notches so as to define a locking clip between said narrow throat portion and said open space, wherein said locking clip is movable between a support passing position and a support locking position, wherein in the support passing position said interconnecting members passes through said narrow throat portion and into said wide rear portion, and wherein in the support locking position said interconnecting member is precluded from passing through said narrow throat portion so as to be retained in place in said wide rear portion.
290 . The kit of claim 289 , wherein the ratio of said width to said length of said locking clip is about 5:1.
291 . The kit of claim 282 , wherein said major receiving notches are disposed along the length of both of said first side edge and said second side edge of each of said primary beams.
292 . The kit of claim 291 , wherein said major receiving notches disposed along the length of said first side edge are longitudinally aligned with the major receiving notches disposed along the length of said second side edge.
293 . A kit used for assembling a metal skeleton for the reinforcement of a concrete structure to be formed therearound, the kit comprising:
a plurality of substantially flat formed sheets of metal material having a plurality of primary beams and a plurality of interconnecting members substantially pre-cut therein so as to be retained in place by frangible connection points left uncut in said substantially flat formed sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said substantially flat formed sheets of metal material after shipping to an assembly site; wherein, the interconnecting members interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
294 . The kit of claim 293 , wherein said plurality of primary beams and a plurality of interconnecting members are laser-cut in said plurality of substantially flat formed sheets of metal material.
295 . The kit of claim 293 , wherein said one or more of said substantially flat formed sheets of metal material have assembly instructions for at least a portion of said metal skeleton laser etched thereon.
296 . The kit of claim 306 , wherein said assembly instructions are laser etched on said remainder of one or more of said substantially flat formed sheets of metal material.
297 . A method of producing a flat-shippable three-dimensional concrete reinforcement skeleton for assembly at a site remote from the production site without the need of supplemental cutting or fastening means, said method comprising the steps of:
a) forming from one or more substantially flat sheets of metal material a first plurality of primary beams and a second plurality of interconnecting members substantially pre-cut therein so as to be retained in place within said substantially flat formed sheets of metal material by connection points left uncut in a remainder of said substantially flat formed sheets of metal material, with each of said primary beams having a third plurality of mechanical interlocking means integrally formed thereon adjacent lateral edges of the primary beams; b) loading said substantially flat formed sheets of metal material into one or more shipping containers; c) relocating said one or more shipping containers to said assembly site; d) removing said substantially flat formed sheets of metal material from said one or more shipping containers; e) breaking said frangible connection points; f) separating said primary beams and said interconnecting members from the remainder of the corresponding substantially flat formed sheets of metal material; g) arranging said second plurality of interconnecting members adjacent said first plurality of primary beams with respective ones of said mechanical interlocking means in operatively close proximity to said second plurality of interconnecting members; and, h) fitting said plurality of interconnecting members within respective ones of said plurality of mechanical interlocking means to secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
298 . The method of claim 297 , wherein the primary beams and the interconnecting members are each formed using a laser cutter.
299 . The method of claim 298 , wherein the laser cutter is a CNC laser cutter.
300 . The method of claim 297 , wherein, either before or after step a), but before step b) one or more of said flat sheets of metal material have assembly instructions for at least a portion of said metal skeleton laser etched thereon.
301 . The method of claim 300 , wherein said assembly instructions are laser etched on the remainder of one or more of said flat sheets of metal material.
302 . The method of claim 297 , further comprising the step of forming receiving portions on the primary beams to thereby permit the securing of the primary beams and the interconnecting members one to the other without said supplemental fastening means.
303 . The method of claim 302 , wherein the step of forming receiving portions on the primary beams comprises forming a plurality of major receiving notches on the primary beams.
304 . The method of claim 302 , wherein said plurality of major receiving notches are disposed along the length of at least one of said first side edge and said second side edge of each of said primary beams.
305 . The method of claim 303 , wherein said major receiving notches each have a narrow throat portion defined by first and second facing throat edges and open to the corresponding one of the first side edge and the second side edge of said primary beams, and a wide rear portion open to said narrow throat portion.
306 . The method of claim 303 , wherein said major receiving notches are spaced at regular intervals one from the next along the length of at least one of said first side edge and said second side edge.
307 . The method of claim 303 , further comprising the step of forming an open space disposed adjacent said first throat edge of the narrow throat portion of said major receiving notches so as to define a locking clip between said narrow throat portion and said open space.
308 . A method of providing the components of a flat-shippable three-dimensional concrete reinforcement skeleton for assembly at a site remote from the production site without the need of supplemental cutting or fastening means, said method comprising the steps of:
a) forming from one or more substantially flat sheets of metal material a first plurality of primary beams and a second plurality of interconnecting members substantially pre-cut therein so as to be retained in place within the substantially flat formed sheets of metal material by frangible connection points left uncut in a remainder of said substantially flat formed sheets of metal material, with each of said primary beams having a third plurality of mechanical interlocking means integrally formed thereon adjacent lateral edges of the primary beams; b) loading said substantially flat formed sheets of metal material into one or more shipping containers; and, c) relocating said one or more shipping containers to said assembly site.
309 . The method of claim 308 , wherein, the interconnecting members interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
310 . The method of claim 308 , wherein said plurality of primary beams and a plurality of interconnecting members are laser-cut in said plurality of substantially flat formed sheets of metal material.
311 . The method of claim 308 , wherein said one or more of said substantially flat formed sheets of metal material have assembly instructions for at least a portion of said metal skeleton laser etched thereon.
312 . The method of claim 310 , wherein said assembly instructions are laser etched on said remainder of one or more of said substantially flat formed sheets of metal material.
313 . A method of assembling a metal skeleton from a plurality of substantially flat formed sheets of metal material having a plurality of primary beams and a plurality of interconnecting members substantially pre-cut therein so as to be retained in place by frangible connection points left uncut in said substantially flat formed sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of said substantially flat formed sheets of metal material after shipping to an assembly site, for the reinforcement of a concrete structure to be formed therearound, the method comprising the steps of:
a) separating said plurality of primary beams and said plurality of interconnecting members from the remainder of the corresponding one of said substantially flat formed sheets of metal material; and, b) interlocking said plurality of interconnecting members with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
314 . The method of claim 313 , wherein, the interconnecting members interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means, to thereby assemble said metal skeleton.
315 . The method of claim 313 , wherein said plurality of primary beams and a plurality of interconnecting members are laser-cut in said plurality of substantially flat formed sheets of metal material.
316 . The method of claim 313 , wherein said one or more of said substantially flat formed sheets of metal material have assembly instructions for at least a portion of said metal skeleton laser etched thereon.
317 . The method of claim 316 , wherein said assembly instructions are laser etched on said remainder of one or more of said substantially flat formed sheets of metal material.Join the waitlist — get patent alerts
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