CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is based upon and claims priority to US Provisional Application No. US 63/408,508, filed on September 21, 2022, which application is hereby incorporated by reference herein.

FIELD

[0002] This disclosure is related to construction of concrete structures.

BACKGROUND

[0003] Concrete structures, for example a concrete wall, may be constructed by tying rebar, building temporary forms out of wood, metal, foam, or plastic, and then placing the concrete in the space created by the forms. Once the concrete has set and cured, the forms are removed. After the forms are removed, problems and issues, for example inadequate or improper consolidation of the concrete, may be revealed that require repair or total reconstruction. Constructing structures using temporary forms can be time consuming, costly, and wasteful. [0004] 3D printing can create concrete structures with minimal or no temporary forms. Typically, 3D printing involves layering thin layers (generally 1-3 inches) of mortar from above to form a border or formwork for other parts of the structure. Mortar may be more costly, may result in more cracking in the structure, may be less durable, and less sustainable than mixtures that contain large aggregates that match conventional concrete mixes. Further, when 3D printing is done from above, the mixture cannot print around rebar. Instead, cavities created by 3D printed formwork may be filled with rebar and then filled with a conventional concrete mixture.

[0005] Devices, systems, and methods that simultaneously or substantially simultaneously place and form a concrete structure that contains rebar, while using only minimal or no temporary formwork would be advantageous.

SUMMARY

[0006] Disclosed herein is a system for forming a concrete member, the system comprising a first side plate, a second side pate, a first consolidation plate, and a second consolidation plate. The first defines a delivery opening for permitting flow of a cementitious mixture therethrough. The second side plate is spaced from and movable with the first side plate. The first side plate and second side plate define a space therebetween. The first consolidation plate is mounted along atop edge of the first side plate. The second consolidation plate is mounted along a top edge of the second side plate. The first and second consolidation plates extend toward one another and are oriented transversely to the first and second side plates. The first and second side plates are movable in a first pass along a travel path such that the cementitious mixture is received in the space through the deliver}’ opening and consolidated in the space as the first and second side plates move along the travel path.

[0007] Also described herein is a method of creating a concrete member. The method comprises positioning a plurality of reinforcement members in a travel path of a concrete member creating device. The method comprises moving the concrete member creating device along the travel path past the reinforcement members. The method comprises delivering a cementitious mixture into a space defined by the concrete member creating device through a side of the concrete member creating device as the concrete member creating device moves along the travel path. The method comprises pressurizing the cementitious mixture within the concrete member creating device as the concrete member creating device is moved to create a first layer of the concrete member.

[0008] Additional aspects of the system and method will be set forth, in part, in the detailed description, and claims which follow, and in part will be derived from the detailed description, or can be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplar - and explanatory only and are not restrictive of the systems and methods as disclosed.

DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is an end view of the system of the current disclosure.

[00010] FIG. 2 is a side view depicting the system of the current disclosure as a concrete member is created.

[00011] FIG. 3 is a side view showing a multiple layer structure created utilizing the system and method of the current disclosure.

[00012] FIG. 4 shows a concrete member forming device creating a thicker pour by using drop down plates.

[00013] FIG. 5 is a view looking down at the interior of a container that may be used in the cunent system. [00014] FIG. 6 is a cross section from line 6-6 of FIG. 5.

[00015] FIG. 7 is a cross section from line 7-7 of FIG 5.

[00016] FIG. 8 is a perspective view of the concrete member creating device of the current disclosure.

[00017] FIG. 9 is a view looking down at the concrete member creating device.

[00018] FIGS. 10 and 11 are views of a bracket utilized to connect support arm to the concrete member creating device.

[00019] FIG. 12 is a perspective view showing drop down plates connected to the second side plate of the concrete member forming device.

[00020] FIG. 13 is a cross section through lines 13-13 in FIG. 9.

[00021] FIG. 14 shows drop down plates connected to the first side plate of the concrete member creating device.

[00022] FIG. 15 is a cross section through line 15-15 of FIG. 9.

[00023] FIG. 16 is a view of the upper connection of the support arm beams.

[00024] FIG. 17 is a schematic of a system using multiple transport units for a concrete member creating device.

[00025] FIG. 18 is a table providing an exemplary cementitious mix that may be used with the system of the current disclosure.

[00026] FIG. 19 is a schematic top view of another example concrete member creating device according to the invention.

[00027] FIG. 20 is a schematic side view of the concrete member creating device shown in FIG. 19.

[00028] FIGS. 21-23 are schematic end view s of the concrete member creating device show n in FIG. 19.

[00029] FIG. 24 is a schematic side view of the concrete member creating device shown in FIG. 19 in operation.

[00030] FIG. 25 is a schematic top view of another example concrete member creating device according to the invention. [00031] FIG. 26 is a schematic of the example concrete member creating device shown in FIG. 25 in use.

[00032] FIG. 27 is a schematic end view of the example concrete member creating device shown in FIG. 25.

[00033] FIG. 28 is a schematic top view of another example concrete member creating device according to the invention.

[00034] FIG. 29 is a schematic end view of the example concrete member creating device shown in FIG. 28.

[00035] FIGs. 30A and 30B show a schematic side view of an example inner side plate. FIG. 30A shows a schematic view of an example nozzle expansion. FIG. 30B shows a schematic view of an example nozzle expansion and nozzle extension.

[00036] FIG. 31 is a view of the upper connection of the support arm beams modified for width adjustment of the concrete member creating device shown in FIG. 8.

[00037] FIG. 32 shows an example 3D concrete printer navigation and position system according to the invention.

[00038] FIG. 33 shows another example 3D concrete printer navigation and position system according to the invention.

[00039] FIG. 34 shows a top schematic view of another example 3D concrete printer navigation and position system according to the invention.

[00040] FIG. 35 shows a top schematic view of another example 3D concrete printer navigation and position system according to the invention.

[00041] FIG. 36 shows a top schematic view of another example 3D concrete printer navigation and position system according to the invention.

DETAILED DESCRIPTION

[00042] Referring now to the figures, a system 5 for creating and forming a concrete member 6 is shown. In one embodiment, the system 5 is a system for creating a concrete member 6 which may be for example a concrete wall of a desired length and width while only using stationary' formwork or existing material that is perpendicular to the length of the wall at the starting and ending of the wall but not on the sides thereof. Stationary concrete form works are supports typically made out of wood, metal, foam and sometimes plastic to support wet concrete while it is placed. These forms are stationary during the construction of the concrete member and stay in place until the member gains a sufficient strength. These forms are then typically removed and are reused or occasionally stay in place. The embodiment of system 5 is suitable for carrying out methods to manufacture concrete member 6 as an upright concrete wall on a surface 7. Concrete member 6 has a rear end 9 and a forward end 11. However, systems 5 and 5a may also be used to practice methods that produce other concrete members, such as slabs, beams and other members. Thus, while the exemplary concrete member 6 is shown as a straight, upright member, it is understood that the device and methods claimed herein may be used in various embodiments to create slanted members and curved members. System 5 may comprise a container 10 for receiving a cementitious mix which may in one embodiment be a cementitious mix that retains its shape after placement without the need for stationary’ forms along the length of the concrete member 6. While there is no need for stationary forms along the length of the concrete member creating device 20. stationary formwork or existing material that is perpendicular to the length of the wall may be used at the starting and ending of the wall but no stationary' forrmvork is used on the sides. Container 10 may be for example a hopper for receiving the cementitious mix.

[00043] System 5 includes a delivery’ pipe 15 is connected to container 10 at one end and at another end to a concrete member creating device 20 yvhich in one embodiment may be referred to as concrete wall creating device 20. Concrete member creating device 20 may be referred to herein simply as device 20. Delivery pipe 15 as will be described in more detail will communicate the cementitious mix from container 10 into a concrete member creating space 25 defined by device 20. Concrete member creating space 25 may be at times referred to a wall forming space 25, but will be primarily referred to herein as creating space 25. Device 20 is movable directionally both horizontally and vertically. Horizontal is the direction parallel to surface 7 and vertical is perpendicular to surface 7. Device 20 is movable not only horizontally and vertically, but in a combination of both. In other words, device 20 can be moved at angles that deviate from both the horizontal and the vertical. Delivery' pipe 15 will deliver a cementitious mix from container 10 into space 25 defined by device 20. The cementitious mixture received therein will be squeezed by device 20 as the device 20 moves along travel path 8 from a first width to a second narrower width which may be for example a final desired thickness. In the embodiment shown, the container 10 is slightly tilted in operation, and the cementitious mix enters concrete member forming device 20 at an angle of about 30° from horizontal. Container 10 may also be tilted at an angle in a direction in and out of the page as shown in FIG. 1 from perpendicular by about 30°. The angles herein are exemplary, and it is understood that container 10 can be positioned and oriented as necessary so that the cementitious mix will be delivered into creating space 25. Device 20 forms and provides a desired surface finish on the concrete member 6. In addition, device 20 consolidates the cementitious mix around reinforcement members 22.

[00044] In one described embodiment a support arm 30 connects container 10 to device 20. The connection of support arm 30 to container 10 and device 20 is such that container 10 and device 20 will move simultaneously. The details of device 20 are better seen in FIGS. 8 and 9. In other embodiments independent arms or vehicles may be used to move the different portions of device 20. Device 20 serves as a moving concrete form for constructing concrete members like those described above. One such embodiment is shown schematically in FIG. 17 which will be explained in more detail below.

[00045] Creating space 25 defined by device 20 may comprise a plurality ⁷ of sections, which may include first, second and third sections 34. 36 and 40 respectively. In one embodiment the creating space 25 defined by device 20 narrows from a first width to a second width as the device 20 moves along travel path 8. Thus, creating space 25 may comprise a width 32 in a first section 34. A second section 36 extends rearwardly toward a rear of device 20. First section 36 terminates at and is connected to a third section 40 which has a width 38. As is apparent from the drawings, width 38 is narrower than width 32 such that the cementitious mix received in device 20 will be squeezed from the initial width 32 to a finished width 38 which is a desired width of the concrete member 6 after the device 20 has squeezed the cementitious mix. In operation a cementitious mix is received in first section 34, which may be referred to as a receiving section. As device 20 moves, the cementitious mix passes through second section 36 which converges from first section 34. Second section 36 may thus be referred to as a convergent section 36. Third section 40 is the final section through which the cementitious mix passes and may be referred to as a finish section. Device 20 thus defines a width into which the cementitious mix is received, and in the embodiment described defines a plurality of widths including width 32 and width 38, which is narrower than width 32. While the described embodiment has a narrowing width from the first to the third sections 34 and 40 thereof, it is understood that a device with a consistent, or unchanging width may be used. The device 20 may use the pressure to consolidate or push the concrete into place. Optionally, the device 20 may use pressure from an auger as descnbed herein.

[00046] Device 20 comprises a pair of plates 27. The pair of plates 27 may include a first side plate 42 and a second side plate 44 spaced. Space 25 is defined by and between first and second plates 42 and 44 respectively. In the described embodiment, the first side plate 42 and second side plate 44 have a specific geometry that provides for the creation of a concrete member 6 utilizing the system 5 without the need for stationary’ concrete forms parallel to the long dimension of the concrete member 6.

[00047] Second side plate 44 comprises a first or containment section 46, a second or receiving section 48, a third or convergent section 50 and a fourth or finishing section 52. Second side plate 44 has upper edge 54 and lower edge 56 defining a height 58. Second side plate 44 has interior side 60, exterior side 62, forward edge 64 and rear edge 66 defining a length 68. A plurality of angle brackets 70 are connected to exterior 62. Angle brackets 70 have a bottom surface 72. Second side plate 44 has a drip guard 74 with an inner edge 76 and a bottom surface 78. Angle brackets 70 are connected such that bottom surface 72 is aligned with lower edge 56 of second side plate 44 and bottom surface 78 of drip guard 74. As will be explained in more detail below, angle brackets 70 may be utilized to connect additional plates, referred to as drop down plates, to second side plate 44. Inner edge 76 of drip guard 74 does not extend radially inwardly past the interior side 60 on finish section 52. In other words, inner edge 76 may be coplanar with interior side 60 of second side plate 44 on finishing section 52.

[00048] First side plate 42 has delivery opening 43 defined in a first or receiving section 80. First side plate 42 has a second or converging section 82 and a third or finish section 84. First side plate 42 has upper edge 86, lower edge 88 and a height 90 therebetween. Height 90 is in one embodiment the same as height 58. First side plate 42 has interior side 92, exterior side 93, forward edge 94, rear edge 96 and length 98 between forward and rear edges 94 and 96. A plurality of angle brackets 100 are connected to exterior side 93 and have a lower surface 102 that is coplanar with lower edge 88 of first side plate 42. A drip guard 104 is connected to first side plate 42 and extends inwardly from the interior side 92 along a portion of the length of first side plate 42. Drip guard 104 has inner edge 106 and bottom surface 108. Inner edge 106 is aligned with and coplanar to interior surface 92 in finish section 84 and bottom surface 108 is coplanar with lower edge 88 of first side plate 42 and bottom surface 102 of angle bracket 100. A distance 110 between inner edge 106 of drip guard 104 and inner edge 76 of drip guard 74 is identical to width 38 in finishing section 40 of the device 20.

[00049] Containment section 46 of second side plate 44 serves to prevent concrete from spilling out of the device 20 past forw ard edge 64 of the device 20. Receiving section 48 is generally parallel to the horizontal direction of travel of the concrete forming device 20 as concrete member 6 is being formed and containment section 46 is angled inwardly at an angle 120. Angle 120 may be as desired to contain the cementitious mixture delivered into device 20 and may be for example in a range between 0° and 90°, and further may be in a range between 10° and 20° and in one embodiment about 15°. Convergent section 50 is connected to receiving section 48 and is angled inwardly therefrom at an angle 122. Angle 122 may be for example in the range of between about 5° and about 15° and in one embodiment may be about 10°. Finish section 52 is parallel to the direction of travel of the concrete forming device 20 and an angle 124 is defined between convergent section 50 and finish section 52. Angle 124 may be in a range from about 5° to about 15° and may be in one embodiment about 10°. Thus, convergent section 50 is angled outwardly from finish section 52 at angle 124.

[00050] Receiving section 80 of first side plate 42 is parallel to the horizontal direction of travel of the device 20. An angle 126 is defined at the transition from receiving section 80 to convergent section 82. Angle 126 may be in the range of about 5° to about 15° and in one embodiment is about 10°. An angle 128 is defined at the transition from convergent section 82 to finish section 84. Angle 128 is in one embodiment in the range of about 5° and about 15° and in particular in one embodiment may be about 10°. As is apparent from the drawings finish sections 84 and 52 of first side plate and second side plate 42 and 44, respectively, are parallel and are parallel to the direction of travel of the device 20 along travel path 8. Although specific ranges for angles 120, 122, 124, 126 and 128 are identified herein, it is understood that the angles may be adjusted depending on the type of cementitious mix used, the speed of travel of system 5 and the desired finish. The velocity along the travel path 8 of the device 20 and the cementitious mixture delivery rate are coordinated and controlled to maintain a desired height of the layer of the concrete member being placed.

[00051] Container 10, which may be described as a concrete or cementitious mix receiving container 10, has upper opening 130 through which the cementitious mix may be received. Container 10 defines a hopper interior 131 into which the cementitious mix is poured through upper opening 130. Hopper 10 has right side wall 132 and left side wall 133. Right and left side walls 132 and 133 slope inwardly from the upper ends thereof toward a bottom 138 of container 10. Container 10 has forward end wall 134 and rear end wall 136. Bottom 138 is a curved bottom to provide for the placement of an auger 140 therein.

[00052] Auger 140 comprises an auger shaft 142 with auger flights 144. Auger flights 144 may be of the type that have rubber tips on the end thereof. One type of auger may be for example a rubber flighted auger manufactured by Danuser ®. Auger 144 is a steel and rubber flighted auger, with the steel flights extended with a strip of rubber at the edge thereof. Auger shaft 142 is rotated by a motor 146 which may be a hydraulic motor, electric motor or any type known in the art to provide rotation. The cementitious mixture may be delivered into hopper 10 via a delivery chute 148 or other means. As is explained in more detail below, the cementitious mix may be delivered by any method such as for example from a ready mix truck, pump, bucket, or other cementitious mix source. An opening 150 which may be referred to as a discharge opening is defined in hopper 10 through the forw ard wall 134 at the forward end thereof. The cementitious mixture delivered into hopper 10 will be delivered and discharged through opening 150 as a result of the rotation of auger 140. The cementitious mixture will be delivered from the hopper interior 131 into delivery pipe 15 and from delivery pipe 15 into the space 25 of device 20 through delivery' opening 43 in first side plate 42. Auger flights 144 will extend past opening 150 and into delivery pipe 15 to urge the cementitious mix into space 25 through opening 43.

[00053] Typically, some form of energy addition is required at the hopper 10 to ensure that the concrete is adequately filling the auger 140. Energy may be added to the concrete mix in the hopper 10 by means of portable concrete vibrators, vibrators physically attached to the hopper 10, and various manual methods such as shoveling and striking the sides of the hopper 10 with rubber mallets.

[00054] A support cage 154 may be connected to hopper 10 to provide structural support thereto and also to provide additional connecting means for support arm 30. Support cage 154 may comprise upper side rails 156, lower side rails 158, upper end rails 160 and low er end rails 162. Vertical support rails 163 may be connected at the comers of support cage 154 to the upper and lower end rails 160 and 162 and the upper and lower side rails 156 and 158. The upper and lower side rails 156 and 158 and upper and lower end rails 160 and 162 may be connected to one another and to container 10 by means known in the art such as for example with bolts, other fasteners or welding. In the embodiment described, stirrups 164 may be connected to lower side rails 158. As will be explained, the stirrups 164 may be utilized as a space for a lifting device to utilize for moving the container 10 horizontally and vertically.

[00055] Support arm 30 may be connected to container 10 with bolts, by welding or other means known in the art. The support arm may be connected directly to container 10, or may be connected to the support cage 154 or both and/or other structural attachment to both. Support arm 30 comprises a first beam 170 connected to container 10 and extending upwardly therefrom. A second beam 172 is connected to first beam 170 and extends downwardly therefrom. The first and second beams 170 and 172 may be connected to one another by a connecting beam 174. The connections may be made by means known in the art such as bolts, welding, and/or pinned hinges. The support arm extends upwardly such that it extends up and over device 20 so as not to impede the travel of device 20 or to prevent the use of reinforcing members 22 in creating space 25 as device 20 travels along travel path 8. Second beam 172 is connected to the exterior side of second side plate 44.

[00056] Because the support arm 30 is connected both to the container 10 and to the device 20, container 10 and device 20 will move simultaneously. Container 10 and device 20 will move together to create concrete member 6. Support arm 30 may be connected to the exterior side 62 of second side plate 44 by means known in the art such as welding and/or fasteners. One embodiment of a bracket 180 for connecting support arm 30 to second side plate 44 is shown in FIG. 1 1. FIGS. 10 and 11 show a bracket 180 and is a multiple piece bracket 180. Bracket 180 comprises a first bracket element 182 that has opposed parallel connecting legs 184. Support arm 30 may be connected to bracket 180 with bolts through legs 184. In the embodiment shown support arm 30 is connected to bracket 180 and to device 20 at the lower end of second support arm beam 172. The support arm may be connected to bracket 180 by welding or other means known in the art. Connecting legs 184 are connected to first and second support plates 186 and 188. An angle 190, which may be for example between 30° and 40°, is defined by and between support legs 184 and support plates 186 and 188, respectively.

[00057] An angle bracket 192 is connected to support plate 188 with a bolt or other means known in the art and is also connected to second side plate 44. Angle bracket 192 is connected to the receiving section 48 of second side plate 44. A second angle bracket 194 is connected to support plate 188, and is connected to second side plate 44 at the convergent section 50. Angle brackets 192 and 194 are positioned such that they define an angle therebetween which matches the angle at the transition between the receiving and convergent sections 48 and 50 of the second side plate 44. This is only one manner of positioning and securing the device 20 to support arm 30, and other connecting means may be used.

[00058] System 5 is a mobile system that may be utilized for vertical concrete construction such as the construction of vertical wall 6. In one embodiment the motive force for moving the device 20 and container 1 may be a transport unit 200 which may comprise for example a track loader, or other moving equipment 202. In such an embodiment, the forks of the track loader 202 will extend into stirrups 164 or may be attached to system 5 by means of mounting plates such as skid steer quick attach mounting system. Track loader 202 can be utilized to move the system 5 in the desired direction, vertically, horizontally or at angles to the vertical and horizontal to create a concrete member of a desired length and height. FIG. 1 depicts the track loader 202 lifting the container 10. Container 10 may be tilted upwardly in a direction such that the container 10 slopes downward toward discharge opening 150. The tilt may be generated by the position of stirrups 164 as shown in FIG. 1, or in some cases tilted by the transport unit 200. Although the embodiment show n herein utilizes a track loader 202, it is understood that other equipment may be used as the transport unit 200, such as skid steers, pow ered industrial trucks, front end loaders and other moving equipment. System 5 may also be attached to a fixed mechanism such as an overhead gantry or track system. The transport units can be operated manually, semi-autonomously or fully autonomously guided with the help of navigation systems.

[00059] FIG. 2 shows a view from the front of system 5 and schematically sho s the container support arm 30, transport unit 200 and device 20. Device 20 is a travelling device 20 in that it will move as transport unit 200 moves container 10 and support arm 30. The view shown in FIG. 2 also includes reinforcing members 22 which may be for example vertical rebar. As shown therein, the reinforcing members 22 are positioned in travel path 8 of the device at selected intervals. Support arm 30 will extend from the container 10 upwardly so that it does not provide any interference and will provide for the placement of concrete around the vertically oriented reinforcing members 22 as each layer of concrete is created.

[00060] FIG. 2 shows a first layer of printed concrete and indicates the direction of movement. As noted, the direction of movement will be such that the cementitious mixture will enter the receiving section 34 of device 20 and will be squeezed by convergent section 36. Thus, device 20 will pass over the cementitious mixture in a direction such that the last contact is through the finish section 40 and a concrete member 6 is created. Finish section 40 will squeeze the cementitious mixture to create the desired finish and also to consolidate the cementitious mixture around the reinforcing members 22.

[00061] FIG. 3 is an illustration of a vertical concrete member 6 with multiple layers printed by the device 20. The cementitious mixture will be delivered into the space 25 defined by the device 20 through delivery opening 43 in first side plate 42. As the device 20 moves along the travel path, the cementitious mixture will be squeezed from the first width 32 in the receiving section 34 to final width 38 in the finish section 40 as it passes through convergent section 36. Once a first layer of the concrete member 6 of a desired length has been placed as depicted in FIG. 2. the device 20 may be lifted and the transport unit 200 utilized to move the device 20 back to a beginning point, for example, a first end of the vertical concrete member 6 being constructed. The process can be repeated in that the transport unit 200 will move horizontally along the travel path 8, the cementitious mixture will be delivered into the device 20 until a second layer of a desired has been printed and placed. This process may be repeated multiple times to create a wall or other concrete member 6 of a desired height as shown for example in FIG. 3. Member 6 of a desired height and width may thus be constructed by making a plurality ⁷ of passes along the travel path with the device 20 at sequentially increasing heights while delivering concrete into space 25 through delivery opening 43 in first side plate 42. The height is increased with each pass so that the layer being created by a single pass along the travel path will be placed atop the previously created layer. Concrete may also be placed continually around a defined perimeter of a structure. This would allow a concrete member to be created from a starting point and the delivery' of a cementitious mix into device 20 would continue such that printing continues until the starting point is reached. The device 20 is then raised and the printing can continue in the same fashion around the perimeter to create additional layers of an enclosed structure. It is also possible to construct discrete members that are not continuous. Device 20 may start at a known place and continue until the end of concrete member 6. While the typical forms used for constructing concrete walls or other structures are not needed, it will be understood that a temporary form may be placed at the beginning point and end point for the structure being constructed or at the ends of walls that intersect another wall. In other w ords, a temporary' form or existing material such as a concrete or steel member may be positioned so that the initial or final placement of concrete has a surface that defines the beginning and ending of the constructed member. For example, as shown in FIG. 3 temporary forms 21 may be placed at the rear and forward ends 9 and 11 of wall 7. The temporary' form 21 at forward end 11 may have a width that will be closely received in finish section 40 of device 20 as device 20 passes the form 21.

[00062] Having described the primary components of system 5, the following will describe in more detail the methods of forming a concrete member using system 5. The following method applies to the formation of an initial concrete member 6 using a cementitious mix on the surface of the ground or other construction surface as well as the extension of concrete member 6 by the addition of subsequent layers to the existing structure. As an initial step, the method provides for the preparation of a mixture suitable for forming into concrete wall 6 or other concrete member such as but not limited to slabs, beams and other members. For the purposes of the following discussion the term concrete will be used to refer to any cementitious mixture regardless of the aggregates used; however, the method applies equally to the use of concrete mixtures that do not use coarse aggregates.

[00063] As an initial step, the cementitious mixture is formed from a dry mix which when combined with water, aggregates and other components has a slump between 0” and about 8”, when measured using American Standard Testing Method C143. The cementitious mix will be designed to have a high amount of cohesion as measured by the ability for the concrete to stack. This is measured by sequentially stacking extruded 4” diameter x 8" long layers that are extruded from plastic molds on top of one another. A cementitious mix of known components is pushed into the plastic mold and is retained therein by placing a closure at the bottom end of the mold. The mold is turned to a generally horizontal position, and a first layer of the cementitious mix is pushed out of the plastic mold. The mix is allowed to rest for a time period, generally between about 10 minutes and 30 minutes, and the change in diameter is then measured across a plurality of axes. A limit of < 10% change in diameter was determined to be the maximum amount of acceptable deviation. The deformation of each layer is measured as more layers are stacked. After a series of tests, the cementitious mix as described herein was selected based on the foregoing, with a rest time of about 20 minutes for each layer. The methods for mixing mixtures having the foregoing characteristics are well known in the art. In general, the dry mix formulation will comprise: portland cement and a supplementary cementitious material such as fly ash, slag, or natural pozzolans; however, these mixtures may contain calcium sulfoaluminate cements or calcium aluminate cements or any other binder. Typically, the dry mix to water mass ratio will be between about 0.40 and 0.50. One nonlimiting example of a cementitious mixture which will be suitable for use in system 5 and having the indicated characteristics is provided by the table in FIG. 18. As shown therein, the cementitious mixture includes aggregate of different sizes (Coarse I and Coarse II and Fine I) portland cement, fly ash and water. When using the mix formulation of FIG. 18, the dry mix to water ratio will be about 0.45. In this mixture a clay rheology modifying admixture is used. Several chemical admixtures are added that aim to disperse the cement grains and to modify the rate of reaction of the mixture. Non-limiting examples of such chemical admixtures include, but are not limited to napholene sulfonates, lignin sulfonates, citric acid, and polycarboxylate ethers. An air entraining agent may also be included to help with finishing and also to impart freeze thaw durability to the concrete. In FIG. 18, the citric acid dosage is .25% by weight of cementitious material (cement and fly ash for the presented mixture). Other formulations which will perform satisfactorily in the following method will be apparent to those skilled in the art. Typically, the cementitious mixture will be formed offsite and transported to the construction site by a ready mix truck or a volumetric mixer. However, onsite preparation of the cementitious mixture is an option. Further, in most formulations, on site addition of additives will not be required.

[00064] Following preparation of the cementitious mixture having the desired characteristics, the resulting mixture is placed in hopper interior 131 defined by container 10 by any convenient means such as delivery' chute 148. As noted above, system 5 is a mobile system. Thus, system 5 will be prepositioned at the desired location prior to engaging auger 140. To initiate construction of concrete member 6, auger 140 located at bottom 138 of hopper interior 131 is engaged. Rotation of auger 140 delivers the cementitious mixture from hopper interior 131 to delivery pipe 15. As the cementitious mixture flows from delivery' pipe 15 into space 25. moving equipment 202 also begins to move device 20 along path 8. As noted above, support arm 30 joins device 20 to container 10. Thus, movement of device 20 will also result in movement of container 10. Thus, the cementitious mixture will continuously' flow from hopper interior 131 to delivery' pipe and space 25 during movement of system 5. Moving equipment 202 may vary from construction site to construction site. As nonlimiting examples, moving equipment 202 may be a track loader: however, in other instances moving equipment may take the form of an overhead support for device 20 and container 10. Other moving equipment like that described above are additional non-limiting examples. Operational control of system 5, including moving equipment may be manual, fully automated or partially automated as determined by the construction product. Likewise, other systems, for example pumps, may be utilized for the delivery of the cementitious mixture. [00065] During formation of concrete member 6, the forward velocity' of moving equipment 202 over travel path 8 will be determined by the physical characteristics of the final cementitious formulation. Typically, the velocity of moving equipment 202 will be between about 0.5 ft/s and 2.0 ft/min. During movement of equipment 202, the operation of auger 140 is managed to ensure a consistent flow' rate of the cementitious mixture. Thus, the operation of system 5 provides a consistent thickness of the cementitious mixture during the formation of concrete member 6.

[00066] Optionally, the formation of concrete member 6 may include reinforcement members 22. When forming concrete member 6 with embedded reinforcement members 22, the reinforcement members 22 will be placed in travel path 8 prior to formation of concrete member 6 by device 20. Typically, reinforcement members 22 wall be placed in travel path 8 prior to initiating operation of system 5. Reinforcement members 22 in one embodiment may be vertically oriented reinforcement members such as for example steel, fiberglass or other reinforcing members. Thus, as system 5 moves along path 8. operating space 25 will encompass reinforcement members 22 as the cementitious mixture flows into operating space 25. The open ended configuration of operating space 25 enables formation of a reinforced concrete member 6, i.e. formation of concrete member 6 around reinforcement members 22. As such, the structural integrity' of concrete member 6 is not subsequently disturbed by placing the reinforcement members into the formed concrete member 6.

[00067] Accordingly, as device 20 moves along path 8, the cementitious mixture floyvs from deliver}' pipe 15, through delivery opening 43 located in first side plate 42 into space 25. In the described embodiment the cementitious mixture is delivered into space 25 through delivery opening 43 defined in first side plate 42. However, other arrangements are possible, so long as the cementitious mixture is delivered into the space 25 as device 20 is moving along travel path 8. As device 20 moves foryvard, the cementitious mixture is squeezed from the first width 32 defined by and between plates 42 and 44 in first section 34 to the second and narrower width 38 defined by and between first and second side plates 42 and 44 in third section 40 which may be the finished yvidth of the concrete member being formed. Thus, as device 20 moves along travel path 8, horizontal in the depictions in FIG. 2, the portion of the concrete member 6 that passes out of the device 20 will remain upright with no stationary forms or other support. In other yvords. the portion of the concrete member 6 will hold the shape created by device 20, whether the orientation is vertical or otherwise, yvithout the use of stationary forms. The squeezing of the cementitious mixture by device 20 creates a desired finish for the concrete member 6 and also consolidates the cementitious mixture around the reinforcing members 22 in finishing section 40. As a result, no additional support is needed for the portion of the concrete member 6, such as for example a vertical concrete wall 6, that is created as the device 20 moves along the travel path 8. In one aspect, the prepositioning of reinforcement members 22 further reduces the need for stationary' forms as concrete member is formed around reinforcement members 22 and is not subsequently disturbed by their introduction to the formed concrete member. Of course, the current method is equally applicable to the formation of concrete member 6 lacking reinforcement members 22 such as rebar or structures that contain fiber reinforcement.

[00068] During formation of concrete member 6, cementitious mixture enters space 25 of device 20. Containment section 46 of second side plate 44 serves to prevent the mixture from spilling out of the device 20 past forward edge 64. As depicted, receiving section 48 is generally parallel to the horizontal direction of travel of the concrete forming device 20 as concrete member 6 is being formed and containment section 46 is angled inwardly at an angle 120. Containment of the cementitious mixture ensures that substantially all of the mixture passing into space 25 of device 20 will be squeezed as it passes from width 32 in section 34 to width 38 in section 40. Since width 38 is narrower than width 32, width 38 defines the finished or desired width of the concrete member 6.

[00069] In certain embodiments drop down plates may be utilized as the device is raised to place the second and higher layers or to print thicker layers. Drop down plates 210 for first side plate 42 are shown in FIGS. 14 and 15. Drop down plates 210 are generally flat plates that are connected with angle brackets 212 to the angle brackets 100 on first side plate 42 or with hinges and brackets. Drop down plates 210 are positioned so that they are directly aligned with, and thus coplanar with finish section 84 on first side plate 42. Drop doyvn plates 214 for second side plate 44 are shown in FIGS. 12 and 14. Drop down plates 214 are connected with angle brackets 216 to angle brackets 70 on second side plate 44. Drop down plates 214 are connected so that they are aligned with, and thus coplanar w ith finish section 52 of second side plates 44. Drop down plates 210 and 214 when utilized will be spaced apart a distance 218 which is identical to width 38 of finish section 40 of space 25. Drop down plates 210 and 214 may be utilized for example to provide additional finish and/or additional support to previously placed layers as the device 20 is moved upwardly to construct a concrete member 6 of a desired height. Alternatively, the drop down plates 210 and 214 may be utilized for example to create thicker layers. The layer thickness may be determined by the adhesion of the concrete and the size of the desired print. However, it is understood that drop dow n plates 210 and 214 are not necessary and that each layer that is placed is self-supporting.

[00070] An embodiment of a system 5a is schematically shown in FIG. 17. System 5a includes a device 20 with a space 25 as previously described. A mixture, for example a cementitious mix is delivered into space 25 from a container 10 through delivery pipe 15. System 5a however includes two separate transport units, identified as transport units 250 and 252. Transport units 250 and 252 may be of the type described herein. Transport unit 250 is connected to container 10 with arms 254 that may be of a type that will extend and retract. Transport unit 252 is connected to second side plate 44 with arms 256, which likewise may be of a type that extend and retract. Transport units 250 and 252 will be in communication such that side plates 42 and 44 are moved at the same rate of speed in the direction along the travel path. In other words, the plates 42 and 44 move synchronously in the direction of the travel path. However, using such a configuration, the first and second plates 42 and 44 are allowed to move independently to the left and/or right as depicted in the figure. Such a configuration allows the construction of a tall structure such as a wall, with a vary ing width, or with a curved outer surface.

[00071] FIGs. 19-25 show another example embodiment of a concrete member creating device 21 according to the invention. Device 21 is similar to device 20 shown in FIG. 8 in that device 21 also comprises a containment section 46, a receiving section 48, a convergent section 50 and a finishing section 52, but additionally has a pair of consolidation plates 23 (FIG. 19) and a pair of drop down plates 25 (FIG. 20). As shown in FIG. 19, consolidation plates 23 are arranged on opposite sides of device 21 downstream of the containment section 46 and are pivotably attached to the upper edges of the plates 27 forming device 21. Pivoting motion of consolidation plates 23 is afforded by hinges 29 and the plates 23 are pivotable between a first position substantially aligned with the plates 27 forming device 21 (FIG. 21) to a second position where consolidation plates are oriented transversely to plates 27 and overlying a section of device 21 as shown in FIG. 22. Optionally, the consolidation plates 23 may extend at an upward angle in the second position overlying a section of device 17 to create a raised area of concrete toward the center of the structure that may act as a water stop and prevent moisture movement between layers. Alternatively, the consolidation plates 23 may be positioned so that there is a gap between opposing plates 23 to allow concrete to seep upward out of the gap to create a raised area of concrete toward the center of the structure that may act as a water stop and prevent moisture movement between layers. In the example embodiment shown, consolidation plates 23 overlie the convergent section 50 (see also FIG. 8), but may also be lengthened or moved further upstream or downstream to overlie another section, such as the receiving section 48, either instead of or in addition to the convergent section 50. Each consolidation plate 23 may also include an upper dropdown plate stabilizer 23a as shown in FIG. 19. Dropdown plate stabilizer 23a could be a leveler to hold the respective consolidation plates 23 in position. The upper dropdown plate stabilizers 23a acting between each consolidation plate 23 and the plates 27 forming the device 21 may be used to contain the concrete. The upper dropdown plate stabilizer 23a can be manually set in place or be coupled with actuators (not shown). In some embodiments the actuators would perform the work of the stabilizer plates and the automation of the actuator setting the plates in place. The actuators may include but are not limited to pneumatic, screw or hydraulic actuators.

[00072] As shown in FIGs. 20 and 21, drop down plates 25 are arranged on opposite sides of device 21 and are pivotably attached to the lower edges of the plates 27 forming the device 21. Pivoting motion of the drop down plates 25 is afforded by hinges 31, and as shown in FIGs. 22 and 23. drop down plates 25 are pivotable outwardly away from one another (FIG. 22) between a first position wherein the drop down plates are oriented transversely to the plates 27 and a second position substantially aligned wdth the plates 27 forming device 21 (FIG. 23). Lower dropdown plate stabilizers 33 may be used to effect the pivoting motion of the drop down plates 25 between the positions shown. The upper dropdown plate stabilizer 23a could hold the consolidation plates 23 in a transverse or near transverse orientation to the plates 27 and could provide downward pressure and shaping to enable and promote finish, shaping and consolidation of the cementitious mixture. In some embodiments the upper dropdown and lower dropdown plate stabilizers 23a and 33 are manually activated devices. Other example embodiments feature dropdown plate stabilizers 23a and 33 activated by power assist systems including but not limited to hydraulic cylinder actuators, electromechanical screw linear actuators, pneumatic cylinder actuators and actuators integrated with four-bar mechanisms. The manual or powder assisted systems could hold the consolidation plates 23 and drop down plates 25 up or down depending on the requirements of the printing operation, system transportation and cleaning. Widths of the consolidation plates 23 could be varied in coordination with width adjustments of the device 21. In some embodiments the drop down plates 25 may attach to plates 27 using sliders that would allow the drop down plates to be mounted nearly flush to the plates 27 when not in use. Actuators may also be used to slide the drop down plates 25 nearly parallel to the plates 27 and into place below plates 27.

[00073] In one embodiment, shown in FIG. 21, the positions of the consolidation plates 23 and the drop down plates 25 at the start of a first pass of device 21 during formation of a concrete member. Consolidation plates 23 are vertically oriented, pivoted away from one another so as not to overlie a section of the device 21, and the drop down plates 25 are pivoted away from one another, oriented transversely to the plates 27 comprising device 21. When, as shown in FIGs. 19 and 22, a cementitious mix is delivered into the containment section 46 through delivery pipe 15, the consolidation plates 23 are pivoted to a position overlying a section (e.g., 48, 50 or 52) of the device 21. The drop down plates 25 remain oriented transversely to the plates forming the device 21 during this first pass. The first pass positions the bottom edges of device plates 27 proximate to ground level, the plates 27 defining the depth of the first course of cementitious mix being printed. The drop down plates 25 remain oriented transversely to plates forming device 21 to provide clearance above the ground 35. Alternatively, drop down plates 25 may be pivoted to a substantially vertical position, substantially parallel and aligned with plates 27, w ith the bottom edges of drop down plates 25 proximate to ground level to print a thicker layer. As device 21 is moved along its path (right to left in FIG. 19) the cementitious mix is forced from the containment section 46 (see also FIG. 8) to the receiving section 48 and then to the convergent section 50 and finally to the finishing section 52. The consolidation plates 23, overlying one or more of the sections downstream of the containment section, act as limiting barriers to provide an approximate uniform height of the first pass of the concrete member being formed and can improve consolidation of the cementitious mixture. As shown in FIGs. 19 and 20, the leading edges 37 of the consolidation plates 23 may be angularly oriented to guide the cementitious mixture downwardly into the section and prevent it from overflowing the device 21.

[00074] FIGs. 23 and 24 show device 21 during a second concrete laying pass. As shown in FIG. 24, device 21 is positioned above the concrete layer 39 formed during the first pass. During the second pass, as shown in FIG. 23, the drop down plates 25 may be pivoted into a substantially vertical position to substantially align with the plates 27 forming device 21 and the consolidation plates 23 are again pivoted to a horizontal position overlying one or more sections of device 21. The drop down plates 25 may be used if the design allows for thicker layers. The cementitious mix is again supplied to the containment section 46 via pipe 15 (see FIG. 19) and the device 21 traverses its path (left to right in FIG. 24), depositing the mix of the second pass on top of the first layer 39 thereby printing a second concrete layer 41. The consolidation plates 23 again act as barriers to ensure an approximate uniform height of the second pass concrete layer 41. The drop down plates 25, now in the vertical position, may support the sides of the first concrete layer 39 to prevent them from bulging outwardly under the weight of the second layer 41. giving the first layer 39 additional time to set and support the weight of the second layer 41 without deforming. Alternatively, the drop dow n plates 25 may be positioned above the first layer 39 and used to form a thicker layer than if plates 27 were used alone. The configuration of the consolidation plates 23 and the drop down plates 25 shown in FIG. 23 is again used for each subsequent layer as the concrete member is formed, pass by pass.

[00075] FIG. 25 shows a concrete member creating device 21a according to the invention. Device 21a is similar to device 21 with the addition of a pair of containment plates 220 and expanded consolidation plates 23 attached to the plates 27 forming the device 21a. Optionally, the plates 27 are parallel or substantially parallel. The device 21a may receive concrete until the space defined by the plates 27, containment plates 220 and consolidation plates 23 is filled with concrete. The containment plates 220 and/or the consolidation plates 23 may be configured to contain and consolidate the concrete within the device 21 as the device 21 is filled. Optionally, the device 21a may be filled with concrete until the concrete begins to seep out between the containment plates 220 and/or consolidation plates 23 thereby ensuring the space defined by the plates 27, containments plates 220 and consolidation plates 23 is completely filled with concrete and the concrete within in the device 21a is consolidated.

[00076] The containment plates 220 may be positioned upstream of the concrete to prevent forw ard spillage of the placed concrete. The containment plates 220 may maximize the pressure within the device 21a to stabilize and promote consolidation of the concrete as the device 21 moves forward. As shown in FIG. 25, containment plates 220 are arranged on opposite sides of device 21 and pivotably attached to the forward edges of the plates 27 forming the device 21a. Pivoting motion of the containment plates 220 may be afforded by hinges 222 which allow the containment plates 220 to pivot between a first position oriented transversely, optionally perpendicularly or substantially perpendicularly, to plates 27 and extending inwardly towards the concrete member creating space 25 (see FIG. 25) to a second position where containment plates 220 are oriented transversely to plates 27 and extending outwardly away from the concrete member creating space 25 (see FIG. 26). As shown in FIG. 25, the containment plates 220 may be in the first position while the device 21a is in use and moving forward. When in the first position, the containment plates 220 contain and confine the concrete within the space 25 and shape the concrete. Optionally, when in the first position, the containment plates 220 may be spaced and positioned to allow the concrete filling the space 25 to seep out of the device 21a when the space 25 is completely filled and overflowing with concrete. As shown in FIG. 26, the containment plates 220 may move to the second position while the device 21a is still in use. In this example, the containment plates 220 are moved to the second position prior to the end of the pass and prior to reaching a perpendicular structure, in this example, a wall. In this example, by moving the containment plates 220 to the second position prior to reaching the end of the pass, the containment plates 220 do not interfere with the end of the pass and the perpendicular structure. Additionally, an end of the structure may be formed by using a vertical header sized to fit between the plates 27 forming the device 21a. The header is held stationary to act as a temporary’ form of the end of the structure. As the device 21a approaches the headers, the containment plates 220 may be moved to the second position. The device 21 a may then continue forward so that the header moves through the device 21a between the plates 27 until the rearward end of the device 21a passes the header. Once the concrete is consolidated against the header via the devices 21a forward movement, the header may be removed.

[00077] As shown in FIG. 27, each containment plate 220 may comprise a first plate 224 and a second plate 226. An upper edge of the first plate 224 may be aligned or substantially aligned with the upper edge of the plates 27 forming the device 21a. The height of the first plate 224 may be the same or substantially the same as the height of the plates 27 forming the device 21a. An upper edge of the second plate 226 may abut or overlap with a lower edge of the first plate 224. The second plate 226 may align with or be substantially aligned with the drop down plates 25. The first plate 224 and the second plate 226 may move from the first position to the second position and vice versa independently from each other. For example, the first plate 224 may be in the first position wfiile the second plate 226 is in the second position thereby allowing the first plates 224 to be used w ithout the second plate 226 to accommodate passes having shallower concrete depths. [00078] As show n in FIG. 25, a latch 228 may be used to lock the containment plate 220 in the first position to prevent the concrete from forcing the containment plate 220 from the first position. The latch 228 may be used to effect pivoting motion of the containment plate 220 between the positions shown. In some embodiments, the latch 228 is a manually activated devices. Other example embodiments feature latches 228 activated by power assist systems including but not limited to hydraulic cylinder actuators, electromechanical screw linear actuators, pneumatic cylinder actuators and actuators integrated with four-bar mechanisms. The manual or power assisted systems may hold the containment plates 220 in the first position or second position depending on the requirements of the printing operation, system transportation and cleaning. Widths and positions of the containment plates 220 may vary' to correspond with width adjustments of the device 21a and placement of rebar and to allow rebar to pass between the containment plates 220 when the containment plates 220 are in the first position.

[00079] FIG. 28 shows a concrete member creating device 21b according to the invention. Device 21b is similar to device 21a with the addition of a nozzle expansion 250 and modified consolidation plates 23. As show n in FIG. 28, optionally, there may be a plurality of consolidation plates 23 on one or both sides of the device 21a. The consolidation plate 23 on the same side as the delivery pipe 15 may be positioned and sized to accommodate the nozzle expansion 250. As shown in FIGs. 28-30B, the nozzle expansion 250 connects to the delivery pipe 15. The nozzle expansion 250 extends from a top portion of the delivery pipe 15 to the delivery opening 43 in a plate 27. The delivery' opening 43 in the plate 27 may extend up to the nozzle expansion as shown in FIG. 30A. The nozzle expansion 250 may extend from the delivery pipe 15 to a point above the upper edge of the plate 27 thereby extending the height of the delivery opening 43. The nozzle expansion 250 is configured to extend a top inner portion of the delivery pipe 15. As shown in FIG. 30A, the nozzle expansion 250 increases the size of the delivery' opening 43. The nozzle expansion 250 increases the area of delivery' pipe 250 at the top thereby increasing the delivered concrete volume to more adequately fill the concrete member creating space 25 (see FIG. 1) between the plates 27. As shown in FIG. 30A, the device 21b may further comprise leak prevention plates 252. The leak prevention plates 252 may be configured to prevent spillage of delivered concrete and ensure the delivered concrete is placed in the concrete member creating space 25. [00080] As shown in FIGs. 28, 29, and 30B, the device 21b may further comprise a nozzle extension 260. The nozzle extension 260 may be attached to the nozzle expansion 250. Optionally, the nozzle extension 260 may be configured to pivot about the nozzle expansion 250 via a hinge 274. The nozzle extension 260 may be configured to pivot between a first position wherein the nozzle extension overlies at least a portion of the concrete member creating space 25 and a second position wherein the nozzle extension extends transversely to the nozzle expansion 250 and outwardly away from the concrete member creating space 25. A latch 262 be may be used to lock the nozzle extension 260 in the first position. The latch 262 may be used to effect pivoting motion of the nozzle extension 260 between the first and second positions. In some embodiments, the latch 262 is a manually activated devices. Other example embodiments feature latches 262 activated by power assist systems including but not limited to hydraulic cylinder actuators, electromechanical screw linear actuators, pneumatic cylinder actuators and actuators integrated with four-bar mechanisms. The manual or power assisted systems may hold the nozzle extension 260 in the first position or second position depending on the requirements of the printing operation, system transportation and cleaning.

[00081] As shown in FIGs. 28 and 29, the nozzle extension 260 may comprise a plate overlying at least a portion of the concrete member creating space 25. The nozzle extension 260 may extend over at least a portion of the containment section 46 and receiving section 48 (see FIG. 19). The nozzle extension 260 may extend over at least a portion of the containment section 46, receiving section 48, and the convergent section 50. The nozzle extension 260 may extend over at least a portion of the containment section 46, receiving section 48, convergent section 50, and the finishing section 52. By further extending the delivery pipe 15, the nozzle extension 260 increases the concrete delivery area. The nozzle expansion 250 and the nozzle extension 60 may be configured to increase the area of the delivery pipe 15 towards the top by approximately 50%. The nozzle expansion 250 and the nozzle extension 260 may enable increased concrete volume to more adequately and sufficiently fill the concrete member creating space 25. The nozzle expansion 250 and/or the nozzle extension 260 may increase the head of the concrete further towards the plate 27 opposing the delivery opening 43 thereby increasing the fill pressure and ensuring the device 21a is adequately filled, the internal voids within the concrete are removed, the surface finish of the concrete is improved, and the concrete is forced to consolidate around the rebar. [00082] It is considered advantageous to allow adj ustment of the lateral spacing between the plates 27 forming the sides of device 21 and thereby define the widths of the containment section 46, the receiving section 48, the convergent section 50 and the finishing section 52 (see FIG. 8). Width adjustment will improve the versatility of device 21, 21a, 21b by allowing concrete layers of vary ing width to be printed. Width adjustment will also allow the plates 27 to be moved outwardly away from the concrete member so as to avoid contacting freshly printed layers when device 21. 21a, 21b is moved by moving equipment 200 (see FIGs. 2 and 3) to establish device 21, 21a, 21b in position to form a second or subsequent concrete layer relative to an existing layer or layers. Width adjustment of device 21, 21a, 21b may be effected by permitting adjustment of the support arm 30 which carries the plates 27. An example embodiment of device 21. 21a, 21b having adjustable width capability is shown in FIG. 31 where the connecting cross beam 174 is fixedly attached to the second beam 172, the first beam 170 being movably attached to the connecting cross beam 174. Fixed attachment of the cross beam 174 and the second beam 172 may be by a bolted or welded connection. Moveable attachment between cross beam 170 and the first beam 170 may be via a pivot joint for rotation or a slotted joint for translation. The six bolts 175, three on each side of the beam, are in slightly oversized holes that enable the beam to pivot, enabling adjustment. The functionality of these bolts can be replaced with other mechanisms including but not limited to a pin and bushing or bearing and shaft. As shown in FIG. 1, the second beam 172 is attached to side plate 44 and supports the side plates 27 comprising one side of the device 21, and the first beam 170 is attached to the container 10 and also supports the side plates forming the other side of device 21, 21a, 21b. As shown with reference to FIGs. 1, 8 and 31, motion of first beam 170 at its connection point with connecting cross beam 174, either or both translation and pivoting motion, permits the lateral spacing between the side plates 27 of the device 21. 21a, 21b to be varied and thus vary the widths of the various sections 46, 48, 50 and 52 and consequently defining the width of a concrete layer or providing clearance between an existing concrete layer and the side plates 27 of device 21. Adjustable control of the spacing betw een the side plates 27 is afforded in the example embodiment shown in FIG. 25 using a threaded rod 43 extending between the first and second beams 170 and 172. Adjusting nuts 45 threadedly engaging rod 43 permit the relative position of the beams 170 and 172 to be adjusted to achieve a desired width of the concrete layer or a desired clearance betw een the side plates 27 and an existing concrete layer. Adjustment of the beam positions may also be effected by actuators, including, for example, hydraulic or pneumatic actuators extending between beams 170 and 172. [00083] FIGs. 32 to 36 show exemplary 3D concrete printer navigation and position systems 300. Printing 3D concrete structures requires positioning and moving the system, such as systems 5 and 5a above, along a specific path and trajectory to form the concrete structure of specified shape and dimensions. Equipment operators and semi -automated or fully automated navigation assisting systems require multiple points of reference to properly position the printing system laterally, longitudinally, vertically, and in the three axes of rotation. The exemplary navigation and position systems 300 may inform an operator 320 of a vehicle 340 and/or system 5, 5a position and trajectory in relation to the specified shape of the concrete structure being printed. 3D concrete printer navigation and position systems 300 may include “hard” sighting systems, cameras, lasers, “string potentiometers,” ultrasonic transmitters/sensors, remote control. GPS, microwaves, and/or any other positioning device or method. The exemplary systems 300 described herein may be adapted for automated operation.

[00084] As shown in FIG. 32, the 3D concrete printer navigation and position system 300 may include at least one laser 310. In the example shown in FIG. 32, two lasers 310 are used. The lasers 310 may provide visible guides for a vehicle operator 320. The operator 320 may use the light reflection position of the laser 310 relative to a target line 330 to maintain the vehicle 340 trajectory. A plurality' of lasers 310 may be used to indicate a distance from the target line 330 and a trajectory of the vehicle 340.

[00085] As shown in FIG. 33, ultrasonic transmitters and sensors 380 may be used to indicate relative position and trajectory. The operator 320 of the vehicle 340 may observe, on a visual electronic monitor 370 in the vehicle 340, the relative position and trajectory' of the vehicle 340 relative to a reference device 360, such as a metal beam or plate. Ultrasonic transmission and reflection 390 via ultrasonic transmitters and sensors 380 and the reference device 360 may be used to determine the position and trajectory. An array of ultrasonic transmitters and sensors 380 may provide signals to a microprocessor which converts the signals into distances. The operator 320 may maintain the desired distance and trajectory using the readings.

[00086] As shown in FIG. 34, a concrete printer navigation and position system 300 may include strings 400, potentiometers 410. and known fixed points 420 to provide relative distance information. The relative distance information may be provided to a microprocessor which may indicate the trajectory and distance from the concrete structure 430 to the operator 320. The operator 320 may use this information to navigate the vehicle 340 and/or printing system 5, 5a. Strings 400 may be disconnected and re-attached to fixed points 420 around a given structure 430 as necessary.

[00087] As shown in FIG. 35, microwave and/or receivers 500 and an onboard microprocessing system and monitors, may be used to inform the operator 320 of positions and trajectory of the vehicle 340 and/or the position of system 5. 5a and assist in manual operation.

[00088] As shown in FIG. 36, the system 300 may include a remote control receiver 510 and remote control 520 to allow the operator 320 to remotely control the vehicle 340 and/or system 5. 5a.

Exemplary Aspects

[00089] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular’ aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[00090] Aspect 1: A device for forming a concrete member, the device comprising: a first side plate defining a delivery' opening for permitting flow of a cementitious mixture therethrough; a second side plate spaced from and movable with the first side plate, the first side plate and second side plate defining a space therebetween; a first consolidation plate mounted along a top edge of the first side plate; and a second consolidation plate mounted along a top edge of the second side plate, the first and second consolidation plates extending toward one another and oriented transversely to the first and second side plates; wherein the first and second side plates are movable in a first pass along a travel path such that the cementitious mixture is received in the space through the delivery opening and consolidated in the space as the first and second side plates move along the travel path.

[00091] Aspect 2: The device of aspect 1, wherein the first and second side plates are parallel. [00092] Aspect 3: The device of aspect 1 or aspect 2, wherein the first side plate is connected to a delivery pipe, wherein the delivery pipe is connected to a container having a receiving opening, wherein the delivery pipe communicates the cementitious mixture to the space defined by the first and second side plates through the delivery opening in the first side plate.

[00093] Aspect 4: The device of aspect 3, wherein the container is connected to a support arm and movably connected to a container transport unit, wherein the support arm is connected to the second plate, and wherein the container and the first side and second side plates are movable together by the container transport.

[00094] Aspect 5: The device of aspect 4, wherein the support arm comprises: a first beam connected to the container and extending upwardly therefrom; and a second beam connected to the first beam, the second beam extending downwardly and connected to an exterior side of the second side plate.

[00095] Aspect 6: The device of aspect 5, wherein the first beam is movably connected to the second beam thereby permitting adjustment of lateral spacing between the first and second side plates.

[00096] Aspect 7: The device of aspect 6, wherein the first beam is connected to a cross beam, the cross beam being connected to the second beam.

[00097] Aspect 8: The device of any one of the preceding aspects, wherein an upper portion of the delivery pipe is connected to a nozzle expansion, wherein the nozzle expansion extends from the delivery pipe to a point above an upper edge of the first side plate, wherein the delivery opening extends to the area defined by the nozzle expansion.

[00098] Aspect 9: The device of aspect 8. wherein the nozzle expansion is connected to a nozzle extension, wherein the nozzle extension comprises a plate overly at least a portion of the space.

[00099] Aspect 10: The device of any one of the preceding aspects, wherein the first side plate is connected to a first transport unit and the second side plate is connected to a second transport unit, wherein the first and second transport units are configured to move the first and second side plates synchronously in the direction of the travel path.

[000100] Aspect 11 : The device of any one of the preceding aspects, wherein the first and second side plates are movable upwardly to an increased height sufficient to provide, in an additional pass along the travel path at the increased height, for the placement of the cementitious mix on top of the cementitious mix delivered through the concrete creating device in the first pass.

[000101] Aspect 12: The device of any one of the preceding aspects, further comprising: a first containment plate movably mounted along a forward edge of the first side plate; and a second containment plate movably mounted along a forward edge of the second side plate, the first and second containment plates being movable relatively to the first and second side plates toward one another to respective positions oriented transversely to the first and second side plates.

[000102] Aspect 13: The device of any one of the preceding aspects, wherein: the first consolidation plate is movably mounted along the top edge of the first side plate; the second consolidation plate is movably mounted along the top edge of the second side plate, the first and second consolidation plates being movable relatively to the first and second side plates toward one another to respective positions oriented transversely to the first and second side plates.

[000103] Aspect 14: The device of aspect 13, further comprising: a first stabilizer acting between the first consolidation plate and the first side plate; a second stabilizer acting between the second consolidation plate and the second side plate, the first and second stabilizers acting as levelers to respectively hold the first and second consolidation plates in the position oriented transversely to the first and second side plates.

[000104] Aspect 15: The device of any one of the preceding aspects, further comprising: a first dropdown plate movably mounted along a bottom edge of the first side plate; a second dropdown plate movably mounted along a bottom edge of the second side plate, the first and second dropdown plates being movable relatively to the first and second side plates toward one another between a first position oriented transversely to the first and second side plates and a second position substantially aligned respectively with the first and second side plates.

[000105] Aspect 16: A system for creating a concrete member, the system comprising: a container for receiving a cementitious mix; a cementitious mix delivery' device; a concrete member creating device connected to the container; a delivery pipe connected to the container and the concrete member creating device, the delivery pipe communicating the cementitious mix from the container into a space defined by the concrete member creating device, the concrete member creating device consolidating the concrete within the space, wherein the container and concrete member creating device are movable together in successive passes along a travel path at sequentially increasing heights as the cementitious mixture is delivered into the space defined by the concrete member creating device to create a concrete member of a desired height and length, wherein each successive pass of the container and concrete member creating device are configured to place cementitious mix on top of the cementitious mix placed in the immediately prior pass, and wherein the concrete member creating device is configured to pressurize the cementitious mix in each successive pass.

[000106] Aspect 17: The system of aspect 16, wherein the concrete member creating device comprises: a first side plate defining a delivery’ opening communicated with the delivery pipe; and a second side plate spaced from the first side plate and movable therewith, the first side plate and second side plate defining the space into which the cementitious mix is delivered.

[000107] Aspect 18: The system of aspect 17, wherein the concrete member creating device further comprises: a first consolidation plate mounted along a top edge of the first side plate; and a second consolidation plate mounted along a top edge of the second side plate, the first and second consolidation plates extending toward one another and oriented transversely to the first and second side plates.

[000108] Aspect 19: The system of aspect 17, wherein the concrete member creating device further comprises: a first containment mounted along a forw ard edge of the first side plate; and a second containment mounted along a forward edge of the second side plate, the first and second containment plates extending toward one another and oriented transversely to the first and second side plates.

[000109] Aspect 20: The system of aspect 17, further comprising a support arm connected to the container and to the second side plate, the support arm configured to extend upwardly from the container and above the first side and second side plates to connect to an exterior side of the second side plate. [000110] Aspect 21: The system of any one of aspects 16-20, wherein the delivery device is positioned in the container.

[000111] Aspect 22: The system of aspect 21, wherein the delivery device comprises a rotating auger.

[000112] Aspect 23: A method of creating a concrete member, the method comprising: positioning a plurality of reinforcement members in a travel path of a concrete member creating device; moving the concrete member creating device along the travel path past the plurality of reinforcement members; delivering a cementitious mixture into a space defined by the concrete member creating device through a side of the concrete member creating device as the concrete member creating device moves along the travel path; and pressurizing the cementitious mixture within the concrete member creating device as the concrete member creating device is moved to create a first layer of the concrete member.

[000113] Aspect 24: The method of aspect 23, further comprising: lifting the concrete member creating device after the concrete member creating device has traveled a desired distance along the travel path to create the first layer of the concrete member; returning the concrete member creating device to a desired location along the travel path; and moving the concrete member creating device above the first layer of the concrete member and along the travel path past the plurality of reinforcement members; delivering a cementitious mixture into a space defined by the concrete member creating device through a side of the concrete member creating device as the concrete member creating device moves along the travel path; and pressurizing the cementitious mixture within the concrete member creating device as the concrete member creating device is moved above the first layer of the concrete member to create a second layer of the concrete member atop the first layer of the concrete member.

[000114] Aspect 25: The method of aspect 24 further comprising; lifting the concrete member creating device after the concrete member creating device has traveled the desired distance along the travel path to create the second layer of the concrete member; returning the concrete member creating device to a desired location along the travel path; and repeating the moving the concrete member creating device step, the delivering step, the pressurizing step, the lifting step, and the returning step above the second layer of the concrete member a desired number of times to create additional layers of the concrete member atop the first and second layers until the concrete member has reached a desired height.

[000115] Aspect 26: The method of any one of aspects 23-25. wherein the concrete member creating device comprises: a first side plate through which the cementitious mix is delivered; and a second plate spaced from the first side plate.

[000116] Aspect 27: The method of aspect 26, further comprising moving the first and second plates with a single transport unit.

[000117] Aspect 28: The method of aspect 26, further comprising moving the first and second side plates in a synchronous manner with first and second transport units respectively .

[000118] Aspect 29: The method of aspect 26, wherein the concrete member creating device further comprises: a first consolidation plate mounted along a top edge of the first side plate; and a second consolidation plate mounted along a top edge of the second side plate, wherein the first and second consolidation plates extend toward one another and are oriented transversely to the first and second side plates.

[000119] Aspect 30: The method of aspect 26, wherein the concrete member creating device further comprises: a first containment mounted along a forward edge of the first side plate; and a second containment mounted along a forward edge of the second side plate, wherein the first and second containment plates extend toward one another and are oriented transversely to the first and second side plates.

[000120] Aspect 31: The method of aspect 26, wherein the concrete member creating device further comprises at least one plate movably attached to a front or top edge of at least one of the first side plate and the second side plate, wherein the at least one plate is movable between an open position and a closed position, and wherein the at least one plate is configured to confine the cementitious mixture between the first and second side plates and shape the cementitious mixture.

[000121] Aspect 32: The method of aspect 31, wherein the at least one plate is sized and positioned along the at least one of the first side plate and second side plate to allow the cementitious mixture to seep out of the concrete member creating device when the at least one plate is in the closed position and the concrete member creating device is filled with the cementitious mixture.

[000122] Aspect 33: The method of aspect 31, wherein the at least one plate is sized and positioned along the at least one of the first side plate and second side plate to allow reinforcement members of the concrete member to pass through the concrete member creating device as the concrete member creating device moves to create the first layer of the concrete member.

[000123] Other embodiments of the present invention will be apparent to one skilled in the art. As such, the foregoing description merely enables and describes the general uses and methods of the present invention. Accordingly, the following claims define the true scope of the present invention.