US3640046A

US3640046A - Means for prefabricating brick panels

Info

Publication number: US3640046A
Application number: US4844A
Authority: US
Inventors: Yngve R Anderson; George K Escott
Original assignee: CANADIAN STRUCTURAL CLAY ASSOCIATION
Current assignee: CANADIAN STRUCTURAL CLAY ASSOCIATION
Priority date: 1970-01-22
Filing date: 1970-01-22
Publication date: 1972-02-08
Anticipated expiration: 1989-02-08

Abstract

Prefabricated brick panels are formed course by course on a table, starting against a movable footing course. Course spacers and individual brick spacers are laid in advance of each course and brick respectively. The table has a roller platform projecting from the edge opposite that alongside which the courses are laid. The footing and finished courses are successively pushed towards the platform to bear against it. When sufficient courses are laid to constitute a panel a cement grout is poured between the bricks. As soon as it has stiffened enough to support the bricks as a panel the table is rotated into the vertical and the panel rolled off in the plane. The footing riding the rollers of the platform for further curing of the panel.

Description

0 United States Patent [151 3,640,046

Anderson et al. 1 Feb. 8, 1972 54] MEANS FOR PREFABRICATHNG BRHCK 3,032,850 5/1962 Russell ..25/1 R x PANELS 3,238,589 3/1966 McClamey ..52/749 X [72] Inventors: Yngve R. Anderson, Streetsville, Ontario; P E C F George K. Escott, Willowdale, Ontario, 32: f both of Canada y [73] Assignee: Canadian Structural Clay Association, [57] ABSTRACT wlllowdale Omano Canada Prefabricated brick panels are formed course by course on a [22] Filed: Jan. 22, 1970 table, starting against a movable footing course. Course spacers and individual brick spacers are laid in advance of [21 1 Appl' 4844 each course and brick respectively. The table has a roller platform projecting from the edge opposite that alongside which U-S. B the courses are 'I'he and finished courses are suc. [51] Int. Cl ..E04g 21/22 cessively pushed towards the p|atform to bear again it w [58] Field of Search "52/749, 122; 25/ l 1 l B; sufficient courses are laid to constitute a panel a cement grout 249/ 137 is poured between the bricks. As soon as it has stiffened enough to support the bricks as a panel the table is rotated [56] Reterences cued into the vertical and the panel rolled off in the plane. The foot- UNITED STATES PATENTS ing riding the rollers of the platform for further curing of the panel. 1,623,625 4/1927 Lake ..25/l B 2,807,070 9/l 957 Thomas ..25/1 B 9 Claims, 6 Drawing Figures PATENTEIJ FEB 81372 SHEET 1 OF 2 FIG. I n2 lnven tors YNGVE RANDERSON GEORGE K. ESCOTT mmmm awn SHEET 2' OF 2 FIG.5

Inventors YNGVE R.ANDERSON GEORGE K. ESCOTT by: M

MEANS FOR PREFABRECATING BRICK PAliEllfi This invention relates to a novel method process and apparatus for prefabricating brick panels for transfer from the manufacturing premises to the site on which they are to be erected. In referring to bricks throughout this specification, it as at the outset explained that by such term it is intended to include bricks of all materials, of whatever shape, also hollow tiles, panels of rough faced stone work and all structural monolithic forms to which the method or process described may apply or which may be prefabricated into panel form by the use of the apparatus herein described.

It is common to prefabricate brick panels. One technique consists of prefabricating bricks upon, and bonding the same to, a rear concrete panel. Another consists of prefabricating brick panels upon an easel positioned at an incline or in the subvertical. Still another technique utilizes a table which may be rotated into the vertical after the prefabrication of a panel thereon. To facilitate movement of the panels while fragile because the cement has not been fully cured, dowling of the bricks in various ways has been resorted to, together with other ways of maintaining the integrity of the panel as with a crane or the like to a stacking station such as cramping the panel between opposite edge clamps or clamping bars. All such techniques as are known however are deemed to be too slow or costly, or insusceptible to adequate quality control and hence be liable to unacceptability in meeting building code specifications. All such methods as are known have failed to commend themselves to the brick industry of North America.

The disadvantages of the known prior art may be overcome by the utilization of a powered table, movable between the horizontal and the fully vertical after a set or sufficient number of bricks to form a panel have been laid along one edge of the table following the placement of a footing beam parallel and adjacent to such edge and after a cement grout has been poured on the set of bricks and the same has stiffened enough to permit the table to be rotated into the vertical at which time the weight of the now selfsupporting panel on its footing may be transferred to an elongated roller platform from which it may be rolled off in its plane and parallel to the table surface plane usually onto another set of rollers which set may either be stationary and aligned with additional sets or itself transferrable whereby, if desired, the panels may be stored like library shelving with passages therebetween for inspection of each side and for the free access of curing air, steam, forced draft or the like, all to produce an invention which is believed represents a marked advance in the art from various technical points of view and should effect economies in the manufacturing of prefabricated brick panels thus making such prefabrication economically feasible and competitively equal or advantageous to or over other building means extant in advanced industrial countries.

With the foregoing in view, and such other or further purposes advantages or novel features as may become apparent from consideration of this disclosure and specification, the present invention consists of the inventive concept which is comprised, embodied, embraced, or included in the product, method, process, construction, composition, arrangement or combination of parts, or new use of any of the foregoing, herein exemplified in one or more specific embodiments of such concept, reference being had to the accompanying Figures in which:

FIG. 1 is a perspective representation of the invented table in its vertical position as viewed from the rear, showing a fragment of an adjacent roller platform.

FIG. 2 is a perspective representation of a lower corner of the invented table showing the front thereof, the supporting means or movable footing and roller platform, also the fragmentary portion of an adjacent roller platform being the same as that shown in the accompanying FIG. 1.

FIG. 3 is a perspective representation of the invented table with a completed brick panel lying thereon, in the horizontal, together with a fragmentary portion of an adjacent roller platform as shown in FIGS. 1 and 2.

FIG. 4 is a perspective representation showing an upper front corner of the invented table in vertical position, together with a fragment of a completed panel and one of the stabilizing means.

FIG. 5 is a perspective representation of a fragmentary portion of the means employed for periodically moving completed courses over the table comprising essentially a push rod and an elongated pusher element.

FIG. 6 is a fragmentary perspective representation of the invented table showing the movable footing, a brick spacing means in the form of elongated and short spacing strips, and, in phantom lines the means for periodically moving the courses over the table as depicted in FIG. 5.

In the drawings, like characters of reference designate similar parts in the several Figures.

INTRODUCTORY DESCRIPTION In terms consonant with the invention as claimed, the same consists in terms of a process of placing bricks adjacently upon a table, periodically moving them across the table until the first placed bricks in linear array have been moved near to one edge of the table and all bricks are intercepted against further movement; then inserting a cement grout between the bricks to bond them into panel form and permitting the grout to stiffen until it has reached panel bearing strength. After that rotating the panel into the vertical and moving it away from the table while in the vertical, in a horizontal direction, and in the plane of the panel or in other words parallel with the vertically rotated table. The grout should be of such consistency, and the bricks should have such an initial rate of absorptions as will permit rotation of the panel into the vertical in one continuous motion and its movement away, as aforesaid from the table substantially immediately after the panel has been so rotated.

tated as a method of prefabricating brick panels the invention comprises the method steps of laying successive courses 10 of bricks upon a table 12, moving them when completed over the surface of the table successive into panel-forming adjacency to a location 14 at which a completed panel 16 may be supported after being rotated into the vertical, filling the spaces 18 between the bricks with a cementicious grout when enough courses have been laid to constitute a panel, next allowing the grout to stiffen while upon the table until sufficient panel-bearing strength is reached, then rotating the table with a completed panel upon it into the vertical when the grout has acquired sufficient brick-bearing strength, and then moving the panel while in the said vertical position away from the surface of the table for further curing and storage.

The movement of the panel while in vertical position is horizontal and in its plane. A movable footing is initially placed upon the table, with the first course 22 of bricks against the footing as shown in FIG. 6. The footing is caused to move with the courses over the surface of the table in advance of the leading or footing course until it reaches location 14 (i.e., the location at which a completed panel may be supported upon the footing after the panel has been rotated into the vertical). The footing 20 is caused to rotate with the table being supported at this time at location 14. Brick-spacing means 24 are placed over the table, the bricks 26 being placed between them. The said brick-spacing means 24 are placed between the bricks during the laying of each course and before laying each successive course 10. The brick-spacing method consists of laying an elongated spacing strip equal to the width of a mortar joint beside and parallel with each course upon the completion of that course together with laying a short spacing strip 30 of similar width at right angles to the elongated strip between each brick of each course next following the placing of each brick. The successive courses of bricks are laid upon the table adjacent the edge 32 opposite the edge 34 about which table 12 rotates.

As apparatus the invention comprises means 36 for rotating the table into the vertical following the production of the panel 16, the brick-spacing means 24 aforesaid, panel supporting means 38 comprising at least first means 20 (i.e., the footing so numbered) and second means 40, the second means facilitating the movement of the first means and the panel away from the table upon rotation of the table into the vertical with a self-supporting panel thereon, and means 43 for periodically moving successive courses 10, as completed, toward means 40 until sufficient bricks to constitute a complete panel are in such position with respect to means 40 as to be supported thereby when the table has been rotated into the vertical.

Footing 20 is elongated and second means 40 are secured to table 12 so as to project upwardly therefrom (when the table is horizontal as in FIG. 3 and horizontally therefrom when the table is vertical as in FIG. 2) to intercept the first means or footing 20. The second means 40 also have means 42 for facilitating the movements of the footing 20 with the panel upon it away from the table and in the vertical. Means 42 may also be defined as roller-means and from FIG. 2 it will be seen that they facilitate horizontal movement of the footing and panel in the plane of the panel when vertical. Table 12 is rotatable about edge 34, the courses of bricks being laid adjacent edge 32. Means 42 comprise essentially a push rod 44 and an elongated brick-course contacting pusher element 46. Stabilizing means 48 are provided for use when panel has reached the vertical and permit the panel to move horizontally in the plane thereof. Roller means 42 comprise an elongated platform 50 projecting from table 12 at right angles to the brick contacting surface thereof and relatively adjacent edge 34 which edge of course is the lower edge when the table is rotated into the vertical, platform 50 embodying an elongated frame 52 and a set of parallel rollers 54 transversely spanning the frame so as to lie axially at right angles to the table surface.

DETAILED DESCRIPTION Proceeding to a more detailed description of the invention in general terms to complete the foregoing introductory description, it is explained that the table collectively designated 12 consists essentially of a supporting structure 56 of the form adequately illustrated in the accompanying FIG. 1, the table including a suitable surrounding frame 58 projecting posteriorly of the table supporting plate 60, and bracing generally designated 62 between and within the aforesaid frame.

The table is pivotally mounted upon the supporting structure by means of the bearings 64, the means for rotating the table into the vertical 36 taking the form of pneumatic or the like piston and cylinder assemblies 66 which need not be described in detail beyond stating that they also are pivotally mounted at the lower ends 68 to the pairs of support beams 70 and at the upper ends suitably to the bracing 62.

Upon the two

opposite side edges

72 and 74 of supporting plate 60 and pivotally mounted for rotation as clearly depicted in the accompanying FIGS. 1 and 3 are

sidewalls

76 and 78. By means of the hinge assemblies 80 these sidewalls may be rotated as indicated by arrow 82 clear out of the way of the plane of supporting plate 60 to avoid obstructing the passage of panel 16 when the same travels in the direction of arrow 84 or as best illustrated in the accompanying FIG. 2.

The second means 40 of the panel supporting means 38 is in turn supported upon the set of short channels 86, these channels being welded via the upper flange thereof to the adjacent portion of the surrounding frame 58.

The first means or footing of the panel supporting means generally designated 38 may be a heavy bean of any suitable material such as wood; alternatively it may be in the form of a steel channel or steel box form, It will of course be apparent that the set of parallel rollers 5.4 are joumaled via trunnions projecting into the longitudinal 88 and suitably capped by the bolts 90. The brick-spacing means collectively designated 24 may take any of a variety of forms. It may for example be in the form of a grid which could be lowered onto the table, the bricks 26 being placed within the openings of the grid. The form of brick-spacing means shown however is believed already to have been sufficiently described, it being understood that the

spacing strips

28 and 30 are preferably of rubber, plastic or the like and of square cross section as illustrated. The pusher element 46 is in the form of an elongated plate and it will be noted that the lower edge thereof is rabbetted as at 92 exactly to accommodate one of the elongated spacing strips 28. The stabilizing means 48 more specifically described consists of a set of bearing blocks 94 through the bearings 96 of which extend the rods 98. On the anterior ends of the rods are tubular receptacles 100 to receive the right angularly disposed rods 102. Telescopically related to rods 102 are the rods 104 at the distal ends of which padded discs are attached. The

rods

98, and 102 may be adjusted in the

bearings

96 and 100 as by the tightening screws 108 for example. Rod 104 may be similarly adjusted by means of a tightening screw (not shown) projecting through the pair of outwardly projecting wings 110 (between which the rod 102 may be slotted). The disc 106 may rotate upon the end of the nonrotatable rod 104. Alternatively by means of obvious variations, the rod 104 and the disc may be caused to rotate simultaneously.

OPERATION Brick-placing workers standing along the edge 32 of the table receive bricks in their left hand as from a conveyor belt or the like and place them in courses, it being understood that the footing 20 has previously been laid down. upon the supporting plate 60 parallel with edge 32 and a few inches from it so that at least the first or footing course 22 may be laid against the footing 20. The workers place a brick and then a short spacing strip 30 until the first course is complctcd. When that has been done, an elongated spacing strip 28 is placed against the footing course and the next successive course (shown in full lines in the accompanying FIG. 6) is laid. When one, two, three or four courses have been laid, (according to how far inboard of the edge 32 the footing 20 was initially placed) it will be necessary to move the set of successive courses and the footing 20 rightwardly with respect to the accompanying FIGS. 3 and 6 utilizing the means 42. The pusher element or bar 46 may be manually operated or it may be automatically operated as by pneumatic means. In either event, it will cause the aforesaid courses and the footing to move sufficiently far over supporting plate 60 to permit the laying or placing of the next one or few courses and so on until a panel 16 of sufficient size has been formed. By the time it is formed, as a rule, the footing 20 and the next successive courses will have been moved over sufficiently far to make contact with the second means 40, in other words, the elongated projecting frame and set of

rollers

52 and 54.

A cement grout will now be poured between the bricks and the table will preferably be vibrated by means of the vibrators 112 (FIG. 1). To make certain that the courses and all cores in the bricks are satisfactorily filled. The consistency of the grout should be such that either of itself, or by said consistency combined with previous wetting of the bricks, an initial rate of absorption is achieved such that the grout will acquire adequate bearing strength in, say 15 minutes although of course it is not intended by this statement to indicate any limitation to such period or any period. A 15-minute dwell may however be spent in such operations as rotating the bulkheads or

sidewalls

76 and 78. When the cement has acquired sufficient bearing strength however, the table is rotated as indicated by arrow 114 into the vertical whereupon the means 42, or elongated frame 52 will take the weight of the panel 16 after which the same may be moved in its plane as indicated by arrow 84 in the accompanying FIGS. I and 2 onto an adjacent elongated roller assembly 116, the bearing surface of the rollers 118 being coplanar with the corresponding bearing surface of the set of rollers 54. Two forms of brick course have been depicted, that of FIGS. 2, 3 and 4 wherein they have been laid upon the supporting plate 60 on edge, and FIGS. 5 and 6 where the bricks are shown lying upon the supporting plate in facing contact therewith rather than edge contact. Obviously any form of course-laying may be resorted to with the means and method which have been described. Obviously also other monolithic forms are capable of being prefabricated into panel form within the ambit of this invention, and as soon as a panel 16 has been completely discharged onto the roller assembly l6, sidewalls or

bulkheads

76 and 78 may be rotated into the position of FIG. 1 or 3 again, locked up (by obvious means which have not therefore been detailed) and the table lowered counterclockwise in readiness for prefabrication of the next panel thereon.

CONCLUSION Having regard to the foregoing, generally stated the invented method consists in the individual or collective steps of prefabricating a panel upon a table by prespacing all the bricks thereof before pouring a cement grout over the panel; prepositioning a panel supporting fitting on the table in advance of the first brick course; pushing the courses as they are completed across the table with the supporting footing until the footing is intercepted by a roller panel supporting assembly projecting from the table parallel with and adjacent the edge about which the table rotates into the vertical until the whole panel has been pushed as far as possible; pouring the cement upon the panel to enter the spaces between bricks; rotating the table with completed panel thereon into the vertical; and rolling the panel away from the table while the table is vertical in the plane of the panel.

It should finally be mentioned however in qualification of the foregoing that by the modification of positioning projecting upstanding dowels upon the edge 34 (FIG. 1) of the table attachment of the elongated frame 52 and roller set to the table and consequent rotation with it can be avoided. in such a modification, the frame 52 and set of rollers would simply remain secured to the floor on suitable supports alongside the table. The set of dowels would support the footing beam and brick panel while the table is rotating and in the final stages of rotation these dowels (now practically horizontal and finally completely horizontal) would subside slightly below the level of the bearing plane of the stationary elongated frame which would thereupon take the load of the footing and panel. It should also be noted that although it has been stated that the movable footing is initially placed adjacent the making edge of the table (i.e., in advance of the footing course) this need not necessarily be so. Thus the movable footing could if desired be initially placed against the second means the elongated roller equipped frame 52.

Various modifications may be constructed or performed within the scope of the inventive concept disclosed. Therefore what has been set forth is intended to illustrate such concept and is not for the purpose of limiting protection to any herein particularly described embodiment thereof.

What is claimed is:

1. Apparatus for facilitating the construction of prefabricated brick panels, characterized by the combination with a table of:

i. means for rotating said table into the vertical with a cementitiously grouted and self-supporting brick panel thereon,

ii. means for fabricating said brick panel upon said table, iii brick panel supporting means comprising at least:

a. first means movable with said panel and in contact with the footing course thereof, and,

b. second means in the vicinity of one of the edges of said table for supporting said first means and said panel, said second means facilitating the movement of said first means and said panel away from said table after rotation thereof into the vertical with a self-supporting panel thereon. said first means of said panel-supporting means being In the form of an elongated footing against which the footing or first course of a panel in course of construction is placed, said second means projecting upwardly from said table when said table is horizontal, and rotating with it to intercept and support said first means and said panel.

2. Apparatus according to claim 1 in which said second means are additionally characterized by including means for facilitating the movement of said first means with a completed vertical panel supported thereon, away from said table while in the vertical. 1

3. Apparatus according to claim 2 in which said second means are additionally characterized by including roller means for facilitating horizontal movement of said first means, and movement of said panel away from said table.

4. Apparatus according to claim 3 in which said second means are additionally characterized in that said roller means are so constructed and designed as to facilitate horizontal movement of said first means and said panel in the plane of said panel and hence parallel with said table.

5. Apparatus according to claim 4 in which said roller means comprise an elongated platform projecting from said table at right angles to the brick-contacting surface thereof and relatively adjacent the edge of said table which is lowest when said table is rotated into the vertical, said platform embodying in combination an elongated frame and a set of parallel rollers transversely spanning said frame so as to lie axially at right angles to said table surface.

6. Apparatus according to claim 4 in which said table is rotatable about one edge thereof, said courses of bricks being laid adjacent the opposite edge.

7. Apparatus according to claim 6 in which said means for periodically moving said completed courses over said table comprise essentially a pushrod and an elongated brick-course contacting pusher element secured substantially at right angles to said rod.

8. Apparatus according to claim 7 which includes means for stabilizing said panel when it has reached the vertical, said stabilizing means permitting said panel to move horizontally in the plane thereof.

9. Apparatus according to claim 8 which is also characterized in that said brick-spacing means embody:

i. elongated strips of material equal to the width of a mortar course, said elongated strips being laid on said table beside and parallel with each course upon the completion of each course,

ii. short spacing strips of material equal to the width of each brick course, said short spacing strips being adapted and designed to be laid at right angles to said elongated strips between each brick of each course next following the placing of each brick.

Claims

1. Apparatus for facilitating the construction of prefabricated brick panels, characterized by the combination with a table of: i. means for rotating said table into the vertical with a cementitiously grouted and self-supporting brick panel thereon, ii. means for fabricating said brick panel upon said table, iii. brick panel supporting means comprising at least: a. first means movable with said panel and in contact with the footing course thereof, and, b. second means in the vicinity of one of the edges of said table for supporting said first means and said panel, said second means facilitating the movement of said first means and said panel away from said table after rotation thereof into the vertical with a self-supporting panel thereon, said first means of said panel-supporting means being in the form of an elongated footing against which the footing or first course of a panel in course of construction is placed, said second means projecting upwardly from said table when said table is horizontal, and rotating with it to intercept and support said first means and said panel.

2. Apparatus according to claim 1 in which said second means are additionally characterized by including means for facilitating the movement of said first means with a completed vertical panel supported thereon, away from said table while in the vertical.

9. Apparatus according to claim 8 which is also characterized in that said brick-spacing means embody: i. elongated strips of material equal to the width of a mortar course, said elongated strips being laid on said table beside and parallel with each course upon the completion of each course, ii. short spacing strips of material equal to the width of each brick course, said short spacing strips being adapted and designed to be laid at right angles to said elongated strips between each brick of each course next following the placing of each brick.