US20110296783A1 - Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith - Google Patents
Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith Download PDFInfo
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- US20110296783A1 US20110296783A1 US13/135,082 US201113135082A US2011296783A1 US 20110296783 A1 US20110296783 A1 US 20110296783A1 US 201113135082 A US201113135082 A US 201113135082A US 2011296783 A1 US2011296783 A1 US 2011296783A1
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
- E04B2/16—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element using elements having specially-designed means for stabilising the position
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8635—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0213—Non-undercut connections, e.g. tongue and groove connections of round shape
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0228—Non-undercut connections, e.g. tongue and groove connections with tongues next to each other on one end surface and grooves next to each other on opposite end surface
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
- E04B2002/0247—Strips or bars
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
- E04B2002/0254—Tie rods
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2002/867—Corner details
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
A system of building modules that may readily be assembled into wall structures that, when filled with concrete, form an insulated, roughly-finished wall structure ready to receive both exterior and interior wall treatments. The building modules may be readily assembled by relatively untrained personnel and form walls typically having an overall R-value in the range of approximately 30. The novel building modules eliminate the need for setting traditional concrete forms and of finishing a bare concrete wall. The modules are provided in various lengths, the lengths typically being multiples of 16 inches.
Description
- This application is a Continuation-in-Part application of U.S. patent application Ser. No. 12/288,114 filed Oct. 17, 2008 which is included in its entirety herein by reference.
- The invention pertains to forms for forming concrete-filled walls and, more particularly, to modular, preinsulated forms readily assembled and adapted to receive concrete therein. The modular forms create a concrete-filled wall having a rough finish on both an interior and exterior surface, thereby allowing ready finishing of these surfaces.
- The process of forming vertical walls from poured concrete has been known for centuries. The process, while theoretically simple, typically requires highly skilled laborers and expensive forms to accomplish. Forms may be either built for single use or may be formed from modular sections assembled to the required configuration. Upon curing of the concrete poured therein, the reusable forms are typically removed and stored for later use on another project.
- Insulated concrete walls are sometimes constructed using form assemblies having insulation disposed as a part of the form. The form becomes part of the concrete wall. This type of construction is typically referred to as lost form construction.
- Regardless of the type of form utilized to construct a poured concrete wall, two major problems remain. First, the construction or assembly of forms typically requires skilled labor and is time intensive. When forms are not properly constructed or set, finished walls may be out of square or plumb, be of the wrong dimension, and/or have bulges or other abnormalities. It is not uncommon for it to be necessary to destroy one or more of the poured walls, reset the forms, and re-pour the concrete. This results in further expense as well as delays in the construction project.
- The second problem is that poured concrete walls constructed using forms of the prior art are notoriously difficult to finish.
- Many attempts have been made to overcome one or more of the aforementioned deficiencies in the concrete wall formations processes of the prior art. For example, U.S. Pat. No. 1,892,605 for WALL CONSTRUCTION, issued Dec. 27, 1932 to Paul Betzler provides a series of interlocking components to facilitate constructing a hollow wall structure. The hollow wall may, optionally, be filled with concrete, the interlocking block wall constituting a lost form.
- U.S. Pat. No. 3,410,044 for FOAMED PLASTIC BASED CONSTRUCTION ELEMENTS, issued Nov. 12, 1968 to Gerhard W. Moog provides construction elements that may be stacked and then, optionally, be filled with concrete. Interlocking blocks are optionally provided by Moog.
- U.S. Pat. No. 3,552,076 for CONCRETE FORM, issued Jan. 5, 1971 to Werner K. H. Gregori, discloses a self-supporting concrete form of low-density foamed polymer. Once in place, concrete may be poured into the hollow central space in the form. The forms become part of the finished concrete wall.
- U.S. Pat. No. 4,075,808 for BUILDING CONSTRUCTION SYSTEM USING MORTAR-LESS MODULAR BUILDING BLOCK ELEMENTS, issued Feb. 28, 1978 to Sanford Pearlman teaches another set of interlocking form blocks useful for laying up a modular form for filling with concrete.
- U.S. Pat. No. 4,924,641 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued May 15, 1990 to James H. Gibbar, Jr. teaches a polymer building wall form wherein forms prefabricated of polymer are assembled together, spaced apart by integrally connecting polymer or blocks or spacers and erected upon a foundation footing through their insertion upon L-shaped ties.
- U.S. Pat. No. 5,038,541 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued Aug. 13, 1991 to James H. Gibbar, Jr. provides a form system wherein prefabricated polymer forms are assembled together and spaced apart by integrally connecting polymer blocks, spacers or spool means. The forms may then be erected on a footer or other foundation.
- U.S. Pat. No. 5,107,648 for INSULATED WALL CONSTRUCTION, issued Apr. 28, 1992 to Edward F. Roby teaches an insulated form system wherein the thickness of the wall may be varied.
- U.S. Pat. No. 5,323,578 for PREFABRICATED FORMWORK, issued Jun. 28, 1994 to Claude Chagnon et al. provides a prefabricated, collapsible formwork assembly.
- U.S. Pat. No. 5,311,718 for FORM FOR USE IN FABRICATING WALL STRUCTURES AND A WALL STRUCTURE FABRICATION SYSTEM EMPLOYING SAID FORM, issued May 17, 1994 to Jan P. V. Trousilek discloses a plastic prefabricated form system.
- U.S. Pat. No. 5,570,550 for INSULATED WALL CONSTRUCTION, issued Nov. 5, 1996 to Edward F. Roby teaches another insulated form system wherein the thickness of the wall may be varied.
- U.S. Pat. No. 5,625,989 for METHOD AND APPARATUS FOR FORMING OF A POURED CONCRETE WALL, issued May 6, 1977 to Thomas R. Brubaker et al. discloses a form system wherein two identically configured panel members each define slots adapted to receive interconnecting flanges of connecting members.
- U.S. Pat. No. 5,860,262 for PERMANENT PANELIZED MOLD APPARATUS AND METHOD FOR CASTING MONOLITHIC CONCRETE STRUCTURES IN SITU, issued Jan. 19, 1999 to Frank K. Johnson teaches an interconnectable system of panels useful for casting a concrete wall.
- U.S. Pat. No. 6,170,220 for INSULATED CONCRETE FORM issued Jan. 9, 2001 to James Daniel Moore, Jr. shows an insulated concrete form system having at least one longitudinally-extending side panel and at least one web member partially disposed in the side panel.
- U.S. Pat. No. 6,178,711 for COMPACTLY-SHIPPED SITE-ASSEMBLED CONCRETE FORMS FOR PRODUCING VARIABLE-WIDTH INSULATED SIDEWALL FASTENER-RECEIVING BUILDING WALLS, issued Jan. 30, 2001 to Andrew Laird et al. discloses a form system of polymer sheets (e.g., polyurethane or expanded polystyrene) that may be fabricated on site to provide concrete forms.
- U.S. Pat. No. 6,263,628 for LOAD BEARING BUILDING COMPONENT AND WALL ASSEMBLY METHOD, issued Jul. 24, 2001 to John Griffin G. E. Steel Company provides a panelized form system that may be erected and then filled with concrete.
- U.S. Pat. No. 6,321,498 for FORMWORK FOR BUILDING WALLS, issued Nov. 27, 2001 to Salvatore Trovato teaches a formwork consisting of a plurality of pairs of facing panels connected together to form an inside space to receive concrete.
- U.S. Pat. No. 6,363,683 for INSULATED CONCRETE FORM, issued Apr. 2, 2002 to James Daniel Moore, Jr. provides another insulated concrete form system having at least one longitudinally-extending side panel and at least one web member partially disposed in the side panel.
- U.S. Pat. No. 6,438,918 for LATCHING SYSTEM FOR COMPONENTS USED IN FORMING CONCRETE STRUCTURES, issued Aug. 27, 2002 to James Daniel Moore, Jr. et al provides latching mechanisms for frictionally holding connectors or the like in position within a concrete form assembly.
- U.S. Pat. No. 6,691,481 for CORNER FORM FOR MODULAR INSULATING CONCRETE FORM SYSTEM, issued Feb. 17, 2004 to Donald L. Schmidt provides a corner form module.
- Published United States Patent Application No. 2005/0275124 for INSULATED CONCRETE FORM SYSTEMS AND METHODS OF MAKING AND USING THE SAME, published Dec. 15, 2005 upon application by Kenneth Franklin discloses a form system wherein flat insulating panels are tied together by a plurality of tying members.
- Published United States Patent Application No. 2007/0094973 for ASSEMBLAGE CONCRETE FORMS AND METHOD FOR MANUFACTURING THEREOF, published May 3, 2007 upon application by Qinjiang Zhu discloses a form system where steel mesh plates and a plurality of joining pieces in cooperation with insulating sheets are assembled to construct a concrete form.
- None of the patents and published patent applications, taken singly, or in any combination are seen to teach or suggest the novel building module form units of the present invention.
- In accordance with the present invention there is provided a novel system of building modules that may readily be assembled into wall structures that, when filled with concrete, form a roughly-finished wall structure ready to receive both exterior and interior wall treatments. The modules may readily be assembled by relatively untrained personnel. Finished walls constructed using the novel building modules typically have an overall R-value in the range of approximately 30. The novel building modules eliminate the need for setting traditional concrete forms and for finishing bare concrete walls.
- In an alternate embodiment, the outer walls of the building modules may be shipped to a building site where they may be assembled using metal width bars in lieu of solid top and bottom members. This may reduce the bulk and weight of the building modules being delivered to a construction site.
- It is, therefore, an object of the invention to provide a building module that may be combined with other like building modules to create a pre-insulated, lost form concrete wall.
- It is another object of the invention to provide a building module that is readily assembled into a form for receiving concrete by relatively untrained personnel.
- It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that is readily finishable on both an interior and an exterior surface.
- It is a further object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that, when finished, has an R-value of approximately 30.
- It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that achieves high R-values using a combination of insulating materials and air spaces while minimizing the amount of insulating material.
- It is a still further object of the invention to provide a building module in varied lengths, typical lengths being multiples of 16 inches.
- It is yet another object of the invention to provide a building module that utilizes metal spacing bars in lieu of solid top and bottom members.
- It is an additional object of the invention to provide a building module that may be shipped knocked down to a construction site and assembled thereat.
- Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
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FIG. 1 is a perspective view of a building module in accordance with the invention having a spline and groove module to module sealing system; -
FIG. 2 is a front elevational view of the building module ofFIG. 1 ; -
FIG. 3 a, is a left end elevational view of the building module ofFIG. 1 ; -
FIG. 3 b is a left end elevational view of the building module ofFIG. 1 but having an end sealing member in place therein; -
FIG. 4 is a perspective view of a building module in accordance with the invention having a tongue and groove module to module sealing system; -
FIG. 5 a is a left end elevational view of the building module ofFIG. 4 ; -
FIG. 5 b is a left end elevational view of the building module ofFIG. 4 but having an end sealing member in place therein; -
FIGS. 6 a-6 d are partial top plan views of four configurations of a building module using tongue and groove features for end-to-end module sealing; -
FIG. 7 is a top plan schematic view of a corner building module in accordance with the invention; -
FIGS. 8 a and 8 b are left side and rear elevational schematic views, respectively of building module ofFIG. 7 ; -
FIG. 9 is an exploded, perspective, schematic view of a pair of building modules joined top-to=bottom using a spline; -
FIGS. 10 a-10 d are schematic elevational views showing the layout of a front, right side, back, and left side of a typical building constructed using the building modules in accordance with the invention and -
FIG. 11 is cross-sectional view of a typical wall constructed using the building modules of the invention. - The present invention provides a system of modular building units that may be readily assembled and used to construct an insulated, roughly-finished concrete-filled wall. The modular building units are adapted to receive both exterior and interior wall surface treatments.
- In the United States as well as other localities, standardized dimensions for construction have emerged over the years. For example, sheet materials such as plywood, wallboard, particleboard, etc. are typically supplied in 4-foot widths and 4, 8, 10, or 12-foot lengths. Many building codes require that studs (i.e., upright vertical posts in a building framework or wall) typically be placed on 16-inch centers, a spacing that conveniently accommodates standard 4-foot wide panels. Other such standard measurements for window widths and heights, door widths and heights, etc. have also emerged. The building modules of the present invention are sized and configured to accommodate such standard dimensions.
- Referring first to
FIGS. 1 , 2, and 3 a, there are shown a perspective, a front elevational, and an end elevational, schematic view of abuilding module 100 in accordance with the invention.Module 100 is substantially hollow and has the form of a rectangular parallelepiped. -
Module 100 has a pair of vertical members, frontvertical member 102 a and rearvertical member 102 b, each having an upper edge 124, a lower edge 126, a left edge 128, aright edge 130, a width “L” 122, and a height “H” 132. -
Top member 104 a andbottom member 104 b are both sandwiched between frontvertical member 102 a and rearvertical member 102 b. An upper major surface, not specifically identified, oftop member 104 a is substantially flush with an upper edge 124 of both front and rearvertical members bottom member 104 b is substantially flush with lower edge 126 of both front and rearvertical members -
Top member 104 a andbottom member 104 b are typically secured to frontvertical member 102 a and rearvertical member 102 b using fasteners or adhesive, neither shown. The process and hardware for joining members (for example,top member 104 a to frontvertical member 102 a) one to another is believed to be well known to those of skill in the art and, consequently, neither is discussed in further detail herein. The invention is intended to include any and all suitable processes and/or hardware suitable for joining members one to another. - Typically, pressure treated plywood is used to form front and rear
vertical members bottom member vertical members bottom members - Top front and top rear horizontal support strips 106 a, 106 b, respectively are fastened to respective ones of front
vertical member 102 a and rearvertical member 102 b in respective top front and rear corners adjacent respective points of intersection withtop member 104 a. - Likewise, bottom front and bottom rear horizontal support strips 108 a, 108 b, respectively are fastened to respective ones of front
vertical member 102 a and rearvertical member 102 b in respective bottom front and rear corners adjacent respective points of intersection withbottom member 104 b. - Optional front and rear middle horizontal support strips 150 a, 150 b may be fastened to respective ones of front
vertical member 102 a and rearvertical member 102 b proximate a vertical, midpoint thereof. - In the embodiment chosen for purposes of disclosure horizontal support strips 106 a, 106 b, 108 a, 108 b, 150 a, and 150 b are typically formed from pressure treated 1×2 “nailer” strip or furring strip material. Horizontal support strips 106 a, 106 b, 108 a, 108 b, 150 a, and 150 b typically extend continuously across the entire width, not specifically identified, of respective ones of front
vertical member 102 a and rearvertical member 102 b. - Referring now also to
FIG. 3 b, there is shown an end, elevational view ofbuilding module 100 with a sealed end. Inbuilding modules 100 that must have an end sealed,horizontal support strip end sealing member 158 that is sandwiched between frontvertical member 102 a, rearvertical member 102 b,top member 104 a, andbottom member 104 b. An outer major surface, not specifically identified, ofend sealing member 158 is disposed substantially flush with left edge 128 of both front and rearvertical members FIG. 3 b shows the left end ofbuilding module 100 sealed. However, the right end, not shown, ofbuilding module 100 may likewise be sealed by installing anend sealing member 158 at the right end thereof.End sealing members 158 are typically used to leave window and door openings or the like in the concrete wall to be constructed usingbuilding modules 100. -
Building module 100 hasgrooves 156 disposed in at least one edge, not specifically identified of frontvertical member 102 a and rearvertical member 102 b. In additiontop grooves 152 may be formed along a top edge, not specifically identified, of front and rearvertical members bottom grooves 154 may be formed along a bottom edge, not specifically identified, of front and rearvertical members Grooves spline 160, best seen inFIG. 9 .Spline 160 is used to provide a seal between horizontal and/or vertical seams formed betweenadjacent building modules 100. Note thatFIG. 9 shows spline 160 only between vertically stackedbuilding modules 100. It will be recognized that a similar construction, not shown, may be used to provide end-to-end sealing between a pair of horizontally alignedbuilding modules 100. - Rebar-accepting
holes 114 and half-holes 116 are provided to stabilize reinforcing bar (i.e., rebar) once building modules are laid up into a wall structure and before pouring concrete. The use of rebar to reinforce concrete walls is believed to be well known to those of skill in the art and neither rebar nor its use is further described herein. - Front and rear
foam insulation sheets Insulation sheets Foam sheets - Front and
rear air spaces rear insulation sheets vertical members -
Openings 118 are provided in top andbottom members building modules 100. The assembly and filling ofmultiple building modules 100 is described in detail hereinbelow. - It will be recognized by those of skill in the art that commercially available foam backed plywood may be used for front and rear
vertical members foam insulation rear air spaces rear air spaces - Each
building module 100 has an overall length “L” 122 typically chosen to be a multiple of 16 inches, for example, 16″, 32″, 48″, 64″, 80″, 96″, etc. It will be recognized that other lengths may be provided as needed to construct a particular wall configuration. - While a 16″ fundamental length has been chosen for purposes of disclosure, it will be recognized that other fundamental module lengths compatible with building codes, practices, or traditions in regions other than the United States may be substituted therefore. Consequently, the invention is not limited to the particular dimensions chosen for purposes of disclosure.
- Referring now to
FIGS. 4 , 5 a, and 5 b, there is shown an alternate embodiment of a building module 100 (FIG. 1 ) having a tongue and groove module to module sealing system, generally atreference number 100′.FIG. 4 shows a perspective, schematic view ofbuilding module 100′ whileFIGS. 5 a and 5 b show a left end elevational view of thebuilding module 100′ ofFIG. 4 , and a left end elevational view of thebuilding module 100′ ofFIG. 4 but having an end sealing member in place therein, respectively. The only difference betweenbuilding modules module 100 is equipped withsquare grooves spline 160 whereasbuilding module 100′ is equipped with protrudingtongues 162 on an upper surface and acurvilinear groove 164 on lower surfaces, thecurvilinear groove 164 being sized and configured to receivetongue 162. - It will be recognized that similar tongue and groove arrangements may be provided on ends of
module 100′ to facilitate side-to-side sealing ofmodules 100′ one to another. It will be further recognized that four module configurations may be provided. Referring now toFIGS. 6 a-6 d, there are shown top plan, schematic views of four possible end configurations ofmodule 100′. InFIG. 6 a,module 100′ hasvertical grooves 168 on a left end andvertical tongues 166 on a right end. InFIG. 6 b,module 100′ hasvertical tongues 166 on a left end andvertical grooves 168 on a right end. InFIG. 6 c,module 100′ hasvertical grooves 168 at both a right and a left end thereof. Finally, inFIG. 6 d,module 100′ hasvertical tongues 166 at both a left and a right end thereof. - Referring now also to
FIG. 7 , there is shown top plan view of abuilding module 200 adapted for forming corners in cooperation withbuilding modules 100/100′. A vertically disposedfront member 202 a, a vertically disposedrear member 202 b, a vertically disposed insideside member 202 c, a vertically disposed outsideside member 202 d each has a top edge, a bottom edge, a left edge, and a right edge, an inward facing major surface, and an outward facing major surface, none of which are specifically identified. - Vertically disposed
front member 202 a and vertically disposed outsideside member 202 d are disposed in a mutually orthogonal relationship, meeting atoutside corner 204. A vertically oriented, substantiallysquare member 208 is disposed atcorner 206 contacting the inward facing major surface of vertically disposedfront member 202 a adjacent the right edge thereof and the inward facing major surface of vertically disposed outsideside member 202 d adjacent a left edge thereof. Vertically disposedfront member 202 a and vertically disposed outsideside member 202 d are attached to vertically disposedmember 208 using any suitable hardware or other fastening method. Dimensions of vertically oriented, substantiallysquare member 208 are chosen to be compatible with the interior construction of building module 200 (i.e., with dimensions of other internal members thereof). - Likewise, vertically disposed
rear member 202 b and vertically disposed insideside member 202 c are disposed in a mutually orthogonal relationship and meet at aninside corner 206, a right edge of vertically disposed rear member contacting a forward facing edge of vertically disposed insideside member 202 c. - An L-shaped planar
top member 222 a has a front edge 224, aright edge 226, a first portion of arear edge 228, a first portion of aleft edge 230, a second portion of arear edge 232, a second portion of a left 234. L-shaped planartop member 222 a is sandwiched between vertically-orientedmembers disposed front member 202 a;right edge 226 is abutted against an inward-facing major surface of vertically oriented outsideside member 202 d; first portion ofleft edge 230 is abutted against an inward-facing major surface of vertically-disposed insideside member 202 c; and second portion ofrear edge 232 is abutted against an inward-facing major surface of vertically-disposedrear member 202 b. An outward-facing major surface of L-shaped planartop member 222 a is aligned with an upper edge of all of vertically disposedmembers - Referring now also to
FIGS. 8 a and 8 b, there are shown left side and rear elevational views, respectively ofbuilding module 200 ofFIG. 7 . - An L-shaped
planar bottom member 222 b also has a front edge 224, aright edge 226, a first portion of arear edge 228, a first portion of aleft edge 230, and a second portion of arear edge 232, a second portion of a left 234. L-shapedplanar bottom member 222 b is sandwiched between vertically-orientedmembers disposed front member 202 a;right edge 226 is abutted against an inward-facing major surface of vertically oriented outsideside member 202 d; first portion ofleft edge 230 is abutted against an inward-facing major surface of vertically-disposed insideside member 202 c; and second portion ofrear edge 232 is abutted against an inward-facing major surface of vertically-disposedrear member 202 b. An outward-facing major surface of L-shapedplanar bottom member 222 b is aligned with a lower edge of all of vertically disposedmembers - Top front and top rear horizontal support strips 210 a, 210 b, respectively are fastened to respective ones of front
vertical member 202 a and rearvertical member 202 b in respective top front and rear corners adjacent respective points of intersection with L-shaped planartop member 222 a. - Top left and top right horizontal support strips 210 c, 210 d, respectively are fastened to respective ones of left
vertical member 202 c and rightvertical member 202 d in respective top front and rear corners adjacent respective points of intersection with L-shaped planartop member 222 a. - Likewise, bottom front and bottom rear horizontal support strips 236 a, 236 b, respectively are fastened to respective ones of front
vertical member 202 a and rearvertical member 202 b in respective bottom front and rear corners adjacent respective points of intersection with L-shapedplanar bottom member 222 b. - Likewise, bottom left and bottom right horizontal support strips 236 c, 236 d, respectively are fastened to respective ones of left
vertical member 202 c and rightvertical member 202 d in respective bottom front and rear corners adjacent respective points of intersection with L-shapedplanar bottom member 222 b. - Optional front and rear middle horizontal support strips 238 a, 238 b, respectively, may be fastened to respective ones of front
vertical member 202 a and rearvertical member 202 b, respectively, proximate a vertical midpoint of each thereof. - Optional left and right middle horizontal support strips 238 c, 238 d, respectively may be fastened to respective ones of left
vertical member 202 c and rightvertical member 202 d, respectively, proximate a vertical midpoint of each thereof. - In the embodiment chosen for purposes of disclosure horizontal support strips 210 a-210 d, 236 a-236 d, and 238 a-238 d are typically formed from pressure treated 1×2 “nailer” strip or furring strip material. Horizontal support strips 210 a-210 d, 236 a-236 d, and 238 a-238 d typically extend continuously across the entire width, not specifically identified, of respective ones of front
vertical member 202 a, rearvertical member 202 b, leftvertical member 202 c, and rightvertical member 202 d. Top, bottom and middle horizontal support strips 210 a, 238 a, 236 a, respectively, abut vertically oriented, substantiallysquare member 208 proximateoutside corner 204 - Front
foam insulation sheet 212 a, is attached to inward-facing surfaces of front horizontal support strips 210 a, 236 a, 238 a. - Rear
foam insulation sheet 212 b, is attached to inward-facing surfaces of rear horizontal support strips 210 b, 236 b, 238 b. - Left
foam insulation sheet 212 c, is attached to inward-facing surfaces of left horizontal support strips 210 c, 236 c, 238 c. - Right
foam insulation sheet 212 d, is attached to inward-facing surfaces of right horizontal support strips 210 d, 236 d, 238 d. - Foam insulation sheets 212 a-212 d are typically attached to inward facing surfaces of respective horizontal support strips 210 a-210 d, 236 a-236 d, and 238 a-238 d using an adhesive. Suitable construction grade adhesives are believed to be well known to those of skill in the art and, consequently, are not further described herein.
-
Air spaces insulation sheets vertical members -
Holes 216 and half-holes 218 are provided to receive rebar 614 (FIG. 11 ) when buildingmodules -
Concrete accepting Openings top member 222 a and a corresponding L-shapedplanar bottom member 222 b to allow pouring concrete into the central space remaining withinbuilding modules 200. The assembly and filling ofmultiple building modules - As previously mentioned, building modules (e.g.,
building modules FIG. 3 b shows abuilding module 100 havingend sealing member 158 sealing one end thereof. The same techniques may be used to seal an end ofbuilding module 200. Consequently, sealing an end ofbuilding module 200 is not discussed in further detail herein. - Building
modules modules building module - Referring now also to
FIG. 9 , there is shown an exploded, perspective, schematic view of a pair ofbuilding modules 100 being joined top-to-bottom to one another with anintervening spline 160. It will be recognized that if tongue-and-groove sealing as shown inFIGS. 4 , 5 a, 5 b, and 6 a . . . 6 d is used, nospline 160 is necessary. - It will further be recognized that inter-module sealing may not be necessary in certain operating environments. Therefore, such structures as grooves, tongues, and splines may be eliminated.
- As previously stated,
building modules FIGS. 10 a-10 d, there are shown front, right-side, rear, and left-side elevational views, respectively of a small building illustrating the use of thenovel building modules - In
FIG. 10 a, a door 502 and a window 504 are shown. InFIG. 10 b, an “overhead” orgarage door 506 may be placed. InFIG. 10 c, twowindows FIG. 10 d, asingle window 512 is shown. The presence and/or placements of door 502,windows overhead door 506 are arbitrary and only used to illustrate the flexibility of usingbuilding modules - Referring now to
FIG. 11 , there is shown a cross sectional, elevational view of a typical wall built in accordance with the building modules and method of the present invention, generally atreference number 600. - Building
modules appropriate footer 602 is placed in accordance with local building codes or accepted practices using conventional techniques. - Next,
U-shaped starting channels 604 are secured tofooter 602, typically usingbolts 606 embedded infooter 602 and secured withnuts 608 to thefooter 602. It will be recognized thatfooter 602,bolts 606, andnuts 608 as well as any additional associated hardware, not shown, necessary to fastenU-shaped starting channels 604 tofooter 602 form no part of the invention and are shown merely to showbuilding modules -
U-shaped channels 604 are typically placed at all seams, not specifically identified, betweenbuilding modules footer 602.U-shaped channels 604 are bolted or otherwise fastened tofooter 602 using techniques believed to be well known to those of skill in the art. Consequently, such techniques are not further discussed herein. - Once
U-shaped channels 604 are in place,building modules U-shaped channels 604 in a pattern such as one of the patterns ofFIGS. 10 a-10 d. - As each
building module spline 160 is inserted in grooves 156 (FIG. 1) as discussed hereinabove. Corner building modules 200 (FIG. 7 ) are used to form corners. - When a first course of
building modules spline 160 is inserted intotop grove 152. As eachbuilding module spline 160 forms a guide to align the next course ofbuilding modules bottom groove 154 of the next course ofbuilding modules - It will be recognized that no spline is required when using
building modules 100′ that have tongue-and-groove structures (e.g., 162, 164, 166, 168) that provide sealing betweenbuilding modules 100′. - When all courses of
building modules rebar 614 may be placed vertically in through-holes - Vertical alignment braces 616 are attached to the surface facing the interior of the building being constructed using
building modules interior finish layer 620 to thewall 600 being constructed. - Prior to pouring concrete, the laid-up assembly of
building modules FIG. 6 , methods and materials for aligning and bracing concrete forms are believed to be well known to those of skill in the construction trades. Consequently, such material and methods are not further discussed herein. - Once the
rebar 614 is positioned and the wall is adequately braced,concrete 618 is poured into the interior cavities ofbuilding modules openings - After the concrete 618 cures, an exterior finish, typically at least some combination of building paper, Tyvek® wrap, foam insulation board, etc. 610 is covered by siding 612. In alternate construction, a masonry veneer finish (e.g., brick, stone, etc.), not shown, may be applied to the exterior face of the wall in lieu of
siding 612. - Interior wall finish is typically accomplished by placing foam insulation, not shown, between the studs-formed by vertical alignment braces 616.
Dry wall 620 may then be applied and finished using conventional finishing techniques. - It is estimated that the R-value of the wall of
FIG. 6 is approximately 30. The R-value contribution of each of the wall components is shown in Table 1. -
TABLE 1 Siding with building paper, 2 etc. Outer plywood 1 ¾″ Air gap 1 ½″ foam 7 Concrete 1 ½″ foam 7 ¾″ air gap 1 Inner plywood 1 1″ foam 8 ½″ air gap 1 ½″ drywall 1 Total 31 - The use of
novel building modules - Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
- Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
Claims (18)
1. A building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall, comprising:
a} a pair of vertically disposed, spaced apart planar front and rear members each having a height, a width, a thickness, a top edge, a bottom edge, a right edge and a left edge, and inward facing major surface and an outward facing major surface, said inward facing major surface of said front member facing said inward facing major surface of said rear member;
b) an elongated planar top member having a front edge and a rear edge disposed parallel to a major axis thereof, an inward-facing major surface, and an outward facing major surface, said top member being disposed between said vertically disposed front member and said vertically disposed rear member, said front edge of said top member abutting said inward facing major surface of said vertically disposed front member, said rear edge of said top member abutting said inward facing major surface of said vertically disposed rear member, said outward facing surface of said top member being aligned evenly with said top edge of each of said vertically disposed front member and said vertically disposed rear member, said left edge of said top member being aligned with said left edge of each of said vertically disposed front member and said vertically disposed rear member and said right edge of said top member being aligned with said right edge of each of said vertically disposed front member and said vertically disposed rear member;
c} an elongated planar bottom member having a front edge and a rear edge disposed parallel to a major axis thereof, an inward-facing major surface, and an outward facing major surface, said bottom member being disposed between said vertically disposed front member and said vertically disposed rear member, said front edge of said bottom member abutting said inward facing major surface of said vertically disposed front member, said rear edge of said bottom member abutting said inward facing major surface of said vertically disposed rear member, said outward facing surface of said bottom member being aligned evenly with said bottom edge of each of said vertically disposed front member and said vertically disposed rear member, said left edge of said bottom member being aligned with said left edge of each of said vertically disposed front member and said vertically disposed rear member and said right edge of said bottom member being aligned with said right edge of each of said vertically disposed front member and said vertically disposed rear member, said planar bottom member being disposed substantially parallel to said planar top member, said vertically disposed front member, said vertically disposed rear member, said planar top member and said planar bottom defining a rectangular parallelepiped having a hollow interior region;
d) at least one opening into said hollow interior region disposed in at least one of said planar top member and said planar bottom member, said at least one opening being sized and configured to receive poured concrete for placement in said hollow interior space;
e) at least two parallel horizontal support strips each having a length, a height, a thickness, a left edge, and a right edge disposed on and attached to said inward facing major surface of both of said vertically disposed front member and said vertically disposed rear member, said at least two horizontal support strips being disposed substantially parallel to said respective top and bottom edges of respective ones of said vertically disposed front member and said vertically disposed rear member, said left edge of each of said at least two horizontal support strips being aligned with said left edge of a respective one of vertically disposed front member and said vertically disposed rear member, said right edge of each of said at least two horizontal support strips being aligned with said right edge of a respective one of vertically disposed front member and said vertically disposed rear member;
f) an insulation sheet having a top edge, a bottom edge, a left edge, a right edge, and an outward-facing major surface attached to an inward facing surface of each of said at least two horizontal support strips, said top edge and said bottom edge of said insulation sheet abutting said inward facing major surface of a respective one of said planar top member and said planar bottom member, said right edge and said left edge of said insulation sheet being aligned with respective ones of said right edge and said left edge of respective ones of said vertically disposed front member and said vertically disposed rear member; and
g) an air gap formed between said outward facing major surface of said insulation sheet and an inward facing surface of a respective one of said vertically disposed front member and said vertically disposed rear member.
2. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1 , further comprising:
h) a planar end sealing member having a top edge, a bottom edge, a left edge, a right edge, and an outward facing major surface, disposed at least one position selected from the group: proximate said right edge of said vertically disposed front member, and proximate said left edge of said vertically disposed front member, said planar end member being disposed substantially perpendicular to, each of said vertically disposed front member, said vertically disposed rear member, said planar top member, and said planar bottom member, said top edge of planar end sealing member abutting said inward facing major surface of said planar top member, said bottom edge of planar end sealing member abutting said inward facing major surface of said planar bottom member, said left edge of planar end sealing member abutting said inward facing major surface of a respective one of said vertically disposed rear member and said vertically disposed front member, said right edge of planar end sealing member abutting said inward facing major surface of a respective one of said vertically disposed rear member and said vertically disposed front member, said outward facing major surface thereof being aligned with respective ones of said left edges and said right edges of all of said vertically disposed front member, said vertically disposed rear member, said planar top member, and said planar bottom member.
3. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1 , further comprising:
h) means for supporting rebar disposed in at least one of said planar top member and said planar bottom member.
4. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 3 , wherein said means for supporting rebar comprises a first through-hole in said planar top member and a second through-hole in said planar bottom member, said first through-hole and said second through-hole being aligned to define an axis substantially perpendicular to a major surface of said top member and substantially parallel to said vertically disposed front member and said vertically disposed rear member, said axis being disposed approximately equidistant from each of said vertically disposed front member and said vertically disposed rear member.
5. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1 , further comprising:
h) means for sealing a first of said building modules to a second adjacent one of said building modules to prevent egress of concrete poured into said interior region.
6. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 5 , wherein said means for sealing comprises means for sealing an end surface of said building module to and end surface of a second building module abutted end-to-end thereto.
7. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 5 , wherein said means for sealing comprises means for sealing at least one of a top surface and a bottom surface of a first building module to at least one of a top surface and a bottom surface of a second building module vertically aligned with and adjacent to said first building, module.
8. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 5 , wherein said means for sealing comprises means at least one selected from the group: a tongue-and-groove seal, and a groove and spline arrangement.
9. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1 , wherein said building module comprises a corner building module comprising a first portion and a second portion contiguous with and orthogonal to said first portion.
10. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1 , wherein each of said front vertical member, said rear vertical member, said top member, and said bottom member comprise pressure treated plywood.
11. The building module adapted for modular construction of an insulated, lost form concrete wall as recited in claim 10 , wherein each of said front vertical members and said rear vertical member have a nominal thickness of approximately ¾ inch.
12. The building module adapted for modular construction of an insulated, lost form concrete wall as recited in claim 10 , wherein each of said top member and said bottom member have a nominal thickness of approximately ½ inch.
13. The building module adapted for modular construction of an insulated, lost form concrete wall as recited in claim 1 , wherein said top front horizontal strip, said bottom front horizontal strip, said top rear horizontal strip, said bottom rear horizontal strip, said middle front horizontal strip, and said rear middle horizontal strip comprise pressure treated lumber having a nominal dimension of approximately 1×2 inches.
14. A method of erecting a concrete wall, the steps comprising:
a) providing a foundation adapted to receive a modular, insulated, lost concrete form;
b) attaching a U-shaped starter channel to an upper surface of said foundation;
c) providing a plurality of building modules adapted for modular construction of an insulated, lost form concrete wall, each of said building modules comprising a hollow, rectangular parallelepiped adapted to receive concrete in a hollow interior region thereof, each of said building modules comprising at least two horizontal support strips disposed within said hollow interior region substantially parallel to a major axis thereof and attached to least one of a front vertical member, and a rear vertical member adjacent at least one of a top member and a bottom member and comprising sheet insulation attached to an inward-facing surface of said at least two horizontal support strips, said insulation sheet forming an air cavity between an outward-facing surface thereof and inward-facing surface of a respective one of said front vertical member and said rear vertical member, and an opening sized and configured to receive poured concrete in said interior region disposed in at least one of said top member and said bottom member;
d) placing a first course of said plurality of building modules in said U-shaped starter channel, said plurality of building modules being placed in an abutting, end-to-end arrangement;
e) placing subsequent courses of said plurality of said building modules atop a lower course of said plurality of building modules, said plurality of building modules of each of said subsequent courses being placed in an abutting, end-to-end arrangement to define at least one wall structure;
f) upon completion of said at least one wall structure, placing alignment braces on an interior face of said at least one wall structure; and
g) filling said at least one wall structure with concrete.
15. The method of erecting a concrete wall as recited in claim 14 , the steps further comprising:
h) when required, placing a spline in at least one of the positions: between an end surface of a first of said plurality of building modules and an end surface of an adjacent, abutted one of said plurality of building modules, and between at least one of a top surface and a bottom surface of a first one of said plurality of building modules and a corresponding one of said top surface and said bottom surface of an corresponding one of said plurality of building modules in an adjacent course of building modules.
16. The method of erecting a concrete wall as recited in claim 14 , wherein said providing step (c) comprises providing at least one building module comprising a corner building module comprising a first portion and a second portion contiguous with and orthogonal to said first portion.
17. The method of erecting a concrete wall as recited in claim 16 , wherein said placing step (d) comprises placing said at least one building module comprising a corner building module comprising a first portion and a second portion contiguous with and orthogonal to said first portion.
18. The method of erecting a concrete wall as recited in claim 17 , the steps further comprising:
h) when required, placing a spline in at least one of the positions: between an end surface of a first of said plurality of building modules and an end surface of an adjacent, abutted one of said plurality of building modules, and between at least one of a top surface and a bottom surface of a first one of said plurality of building modules and a corresponding one of said top surface and said bottom surface of an corresponding one of said plurality of building modules in an adjacent course of building modules.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US13/135,082 US20110296783A1 (en) | 2008-10-17 | 2011-06-24 | Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US12/288,114 US20100095623A1 (en) | 2008-10-17 | 2008-10-17 | Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith |
US13/135,082 US20110296783A1 (en) | 2008-10-17 | 2011-06-24 | Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith |
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US12/288,114 Continuation-In-Part US20100095623A1 (en) | 2008-10-17 | 2008-10-17 | Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith |
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US20110296783A1 true US20110296783A1 (en) | 2011-12-08 |
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US13/135,082 Abandoned US20110296783A1 (en) | 2008-10-17 | 2011-06-24 | Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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FR3085695A1 (en) * | 2018-09-07 | 2020-03-13 | Srp Concept | WALL TRAINING KIT, WALL OR BASE |
EP4273343A3 (en) * | 2014-04-07 | 2024-01-03 | NXT Building System Pty Ltd. | Screw pile for supporting a building structure |
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