Projects

Demonstration Project

Ai-Structural was awarded a business investment grant from the Economic Development Office of Orange County, NC. The grant was used to develop and test prototypes of the company’s products. As part of the demonstration project, masons constructed structural reinforcement of two CMU walls. One wall was built using conventional reinforcement materials and methods. In contrast, the second wall was constructed using Ai-Structural’s products and methods.

The construction was documented on video clips provided in this section. The project demonstrated that the Ai-SP method:

Provided continuous structural reinforcement (from the footing through the CMU walls and through the double top plates). The cables will be connected to the roof trusses in a later phase tying the roof to the footing).
Made a safer working environment for the masons and other workers (by avoiding contact with exposed vertical rebar).
Reduced worker fatigue (eliminated the need for masons to lift heavy CMUs at considerable heights over the rebar).

2min 4sec Option D, with no music.mp4

The two masons each had forty years of experience using rebar for structural reinforcement. However, once the masons became familiar with Ai-Structural’s prototypes and methods they indicated they would be receptive to using the new technique on future projects. They appreciated the safer working conditions and the reduced work effort afforded by the new method. Once masons gain more experience with the new method the end result will be safer, more efficient, and cost-effective projects.

[AI-SP] (#32-3, 32-4, 42) Installing Short Segments of Rebar to Support Cable.mp4

Installing Short Segments of Rebar to Support Cable

[AI-SP] 38, 40 Cutting Cable.mp4

Cutting Cable

[AI-SP] (#57) Introducing New Ai-SP Methods and Devices to Mason.mp4

Introducing New Ai-SP Methods and Devices to Mason

(#65) Laying CMU over Coiled Cable.mp4

Laying CMU over Coiled Cable

(#79) Feeding Cable through Hollow Core of CMU Speed 4x.mp4

Feeding Cable through Hollow Core of CMU

035 (#90) Laying Bond Beams on Top of East Wall.mp4

Laying Bond Beams on Top of East Wall

(#91) Pulling Coiled Cable up with Ai-SP Prototype Coil Retriever.mp4

Pulling Coiled Cable up with Ai-SP Prototype Coil Retriever

037 (#92) Setting Wedge Pins and Connector Clamps on Cable.mp4

Setting Wedge Pins and Connector Clamps on Cable

039 (#93B) Connecting Horizontal and Vertical Cables.mp4

Connecting Horizontal and Vertical Cables

038 (#93A&95) Filling Hollow Cores in Bond Beams with Mortar.mp4

Filling Hollow Cores in Bond Beams with Mortar

051 (#116) Joining Rebar and Cable with Connector Clamp.mp4

Joining Rebar and Cable with Connector Clamp

052 (#117) Holding J-Bolts Temporarily with Wedge Pins.mp4

Holding J-Bolts Temporarily with Wedge Pins

053 (#118) Adding Mortar in Bond Beams with J-Bolts.mp4

Adding Mortar in Bond Beams with J-Bolts

054 (#119) Removing Wedge Pins to Smooth Mortar.mp4

Removing Wedge Pins to Smooth Mortar

055 (#120) Smoothing Mortar around J-Bolts.mp4

Smoothing Mortar around J-Bolts

056 (#121) Replacing Wedge Pins around J-Bolts until Mortar Cures.mp4

Replacing Wedge Pins around J-Bolts until Mortar Cures

062 (#126) Feeding Cable through First Top Plate.mp4

Feeding Cable through First Top Plate

(#127A) Securing Cable with Connector Clamp for Roof Structure.mp4

Securing Cable with Connector Clamp for Roof Structure

064 (#128) Completed Demonstration Project.mp4

Completed Demonstration Project

(#20) Excavating West Footing (Speed 4x).mp4

Excavating West Footing

(#26) Extending Depth of East Footing (4x).mp4

Extending Depth of East Footing

(#27) Removing Debris from Excavation (4x).mp4

Removing Debris from Excavation

(#29) Backfilling Excavation with Gravel (4x).mp4

Backfilling Excavation with Gravel

(#30) Setting Elevations for Footing (4x).mp4

Setting Elevations for Footing

(#32-1,32-2) Installing Vertical Reinforcement.mp4

Installing Vertical Reinforcement

(#32-5) Bending Rebar for Horizontal Reinforcement (4x).mp4

Bending Rebar for Horizontal Reinforcement

(#36) Cutting Rebar 4x.mp4

Cutting Rebar

(#45, 46) Pouring Concrete for Footing.mp4

Pouring Concrete for Footing

(#60) Masons Dodging Rebar During Work (4x).mp4

Masons Dodging Rebar During Work

(#61,63, 64) Working Around Exposed Rebar.mp4

Working Around Exposed Rebar

020 Straddling Rebar During Masonry Work (#62).mp4

Straddling Rebar During Masonry Work

(#75, 76, 77, 78) Lifting CMUs over Rebar.mp4

Lifting CMUs over Rebar

(#82A) 1x Relifting CMU over Rebar to Match Correct Hollow Core.mp4

Relifting CMU over Rebar to Match Correct Hollow Core

(#83) Laying Last CMU in First Course of West Wall.mp4

Laying Last CMU in First Course of West Wall

041 (#98) Working Above Exposed Rebar.mp4

Working Above Exposed Rebar

(#99, 100) Setting Full CMU Over Rebar 4x.mp4

Setting Full CMU Over Rebar

(#103) Setting Half CMUs over Rebar.mp4

Setting Half CMUs over Rebar

045 (#108) Filling Hollow Cores with Mortar (Untied Rebar).mp4

Filling Hollow Cores with Mortar (Untied Rebar)

046 (#110A) Setting Angle Iron for Window Opening.mp4

Setting Angle Iron for Window Opening

047 (#110B) Setting Notched CMU.mp4

Setting Notched CMU

048 (#111) Finding an Alternate Use of Bond Beams.mp4

Finding an Alternate Use of Bond Beams

049 (#114) Laying Bond Beams (West Wall).mp4

Laying Bond Beams (West Wall)

050 (#115) Laying Final Bond Beam (West Wall).mp4

Laying Final Bond Beam (West Wall)

057 (#122) Setting Modified Bond Beam on Angle Iron.mp4

Setting Modified Bond Beam on Angle Iron

(#123A) Lifting Precast Block Lintel.mp4

Lifting Precast Block Lintel

059 (#123B) Laying Precast Block Lintel in Course 12.mp4

Laying Precast Block Lintel in Course 12

060 (#123C) Giving a High Five for a Successful Demonstation Project.mp4

Giving a High Five for a Successful Demonstation Project

061 (#125) Adding Mortar to Final Bond Beam.mp4