System and method of fabricating a reinforced structural member

Abstract

A structural member optimized to resist lateral forces, as well as systems and methods of fabricating and implementing same, are disclosed. In some implementations, a modular framework erected at a work site may support forms used for the fabrication of reinforced concrete or masonry structural members which do not have uniform cross-sectional thickness. The modular nature of the framework allows a construction crew to arrange the forms quickly and precisely on site, and the varying cross-sectional thickness of the structural member and positioning of reinforcing elements economize on materials usage while simultaneously increasing the structural member's resistance to lateral loading.

What is claimed is: 
     
         1 . A structural member comprising:
 a first surface oriented to be substantially vertical, having a first height, and positioned to be exposed to an exterior side of a building;   a second surface oriented to be substantially vertical, having a second height equal to the first height, and positioned substantially parallel to and in a spaced-apart relationship with the first surface, the spaced-apart relationship defining a substantially uniform baseline thickness of the structural member;   a recessed region formed in a portion of the second surface and extending toward the first surface, the recessed region having a recess height that is less than the second height, a recess width that spans a horizontal distance of the second surface, and a recess depth from the second surface that is less than the baseline thickness of the structural member; wherein the recessed region defines an effective thickness of the structural member that is equal to a difference between the baseline thickness and the recess depth; and   a reinforcing element intermediate the first surface and the second surface;   wherein the reinforcing element is disposed intermediate the recessed region and the first surface, supports a portion of the structural member having the effective thickness, and is selectively positioned relative to the first surface such that a resistance to a given bending moment for the structural member as a whole is optimized.   
     
     
         2 . The structural member of  claim 1  wherein a material used for the structural member and defining the first surface and the second surface is concrete. 
     
     
         3 . The structural member of  claim 2  wherein the reinforcing element comprises a steel bar. 
     
     
         4 . The structural member of  claim 3  wherein the reinforcing element comprises a lattice of interconnected steel bars. 
     
     
         5 . The structural member of  claim 2  wherein the reinforcing element comprises a web structure. 
     
     
         6 . The structural member of  claim 5  wherein the web structure comprises a steel mesh. 
     
     
         7 . The structural member of  claim 5  wherein the web structure comprises a fibrous material. 
     
     
         8 . The structural member of  claim 2  wherein the recessed region is symmetrical in planar cross-section. 
     
     
         9 . The structural member of  claim 8  wherein the recessed region is rectangular in planar cross-section. 
     
     
         10 . The structural member of  claim 8  wherein the recessed region is trapezoidal in planar cross-section. 
     
     
         11 . The structural member of  claim 8  wherein the recessed region is curved in planar cross-section. 
     
     
         12 . A method employing a modular framework system to facilitate fabrication of a structural member, the method comprising:
 securing an elongate base plate to a foundation operative to support the structural member, the securing comprising selectively attaching the elongate base plate to the foundation in an orientation substantially perpendicular to a longitudinal axis of a footprint of the structural member;   attaching a column to a portion of the elongate base plate proximate to the footprint of the structural member and bracing the column in a substantially vertical orientation using a brace member attached to a portion of the elongate base plate distal to the footprint of the structural member, the column having a height selected to accommodate a selected height of the structural member;   attaching a top support to the column opposite the elongate base plate and securing the top support in an orientation substantially parallel to a direction of the elongate base plate;   selectively attaching a rail assembly to the top support in a substantially horizontal orientation and substantially parallel to the longitudinal axis of the footprint of the structural member;   selectively suspending an interior form element from the rail assembly to define an interior surface of the structural member;   selectively suspending an exterior form element from the rail assembly a distance from the interior form element to define an exterior surface of the structural member, the distance between the interior form element and the exterior form element defining a baseline thickness of the structural member;   optionally selectively suspending an opening form element to define an opening, in which no structural material will be present, in the structural member, the optionally selectively suspending comprising selectively attaching the opening form element to at least one of the interior form element or the exterior form element;   selectively suspending a reinforcing element from the rail assembly intermediate the interior form element and the exterior form element and positioning the reinforcing element in a position relative to the exterior form element to support the structural member against a bending moment; and   depositing a slurry of construction material in a cavity between the interior form element and the exterior form element to form the structural member having the selected height.   
     
     
         13 . The method of  claim 12  wherein the selectively suspending an interior form element comprises suspending a recess element, having a recess depth from the interior surface of the structural member, that creates a recessed region having an effective thickness that is less than the baseline thickness of the structural member when the slurry is deposited in the cavity. 
     
     
         14 . The method of  claim 13  wherein the recess element is rectangular in planar cross-section. 
     
     
         15 . The method of  claim 13  wherein the recess element is trapezoidal in planar cross-section. 
     
     
         16 . The method of  claim 13  wherein the recess element is curved in planar cross-section. 
     
     
         17 . The method of  claim 13  wherein the selectively suspending a reinforcing element comprises positioning the reinforcing element proximate to the external form element such that the reinforcing element is entirely encased within an area of the structural element having the effective thickness. 
     
     
         18 . The method of  claim 12  wherein the depositing a slurry comprises depositing concrete in the cavity. 
     
     
         19 . The method of  claim 18  further comprising utilizing a trolley that translates on the rail assembly along the longitudinal axis of the footprint of the structural member to deposit the concrete in the cavity. 
     
     
         20 . A modular framework system to facilitate fabrication of a structural member, the system comprising:
 an elongate base plate selectively attached to a foundation, which is operative to support the structural member, in an orientation substantially perpendicular to a longitudinal axis of a footprint of the structural member;   a column attached to a portion of the elongate base plate proximate to the footprint of the structural member and having a height selected to accommodate a selected height of the structural member;   a brace member attached to the column at a location above the foundation and below the height of the structural member and to a portion of the elongate base plate distal to the footprint of the structural member such that the brace member braces the column in a substantially vertical orientation during use;   a top support attached to the column opposite the elongate base plate in an orientation substantially parallel to a direction of the elongate base plate;   a rail assembly attached to the top support in a substantially horizontal orientation and substantially parallel to the longitudinal axis of the structural member;   an interior form element selectively suspended from the rail assembly and defining an interior surface of the structural member;   an exterior form element selectively suspended from the rail assembly a distance from the interior form element to define an exterior surface of the structural member, the distance between the interior form element and the exterior form element creating a cavity that defines a baseline thickness of the structural member;   an opening form element optionally selectively suspended from at least one of the interior form element or the exterior form element to define an opening, in which no structural material will be present, in the structural member; and   a reinforcing element selectively suspended from the rail assembly intermediate the interior form element and the exterior form element and positioned relative to the exterior form element to support the structural member against a bending moment.   
     
     
         21 . The system of  claim 20  wherein the interior form element comprises a recess element, having a recess depth from the interior surface of the structural member, that creates a recessed region having an effective thickness that is less than the baseline thickness of the structural member when a slurry is deposited in the cavity. 
     
     
         22 . The system of  claim 21  wherein the recessed region is symmetrical in planar cross-section. 
     
     
         23 . The system of  claim 22  wherein the recessed region is rectangular in planar cross-section. 
     
     
         24 . The system of  claim 22  wherein the recessed region is trapezoidal in planar cross-section. 
     
     
         25 . The system of  claim 22  wherein the recessed region is curved in planar cross-section.