US 2011/0061336 A1 · Building system, concrete or OSB, pour molded or pressed molded, composite panels, trusses, and products, with engineering methods and fasteners, and related transportation, erection, and materials processing equipment

Abstract

Franchised Building Construction System including Factory Concrete Yard or Site Built Semi Trucked Poured or Pressed Gang Molded Components made of Insulated Pumice and/or Styrofoam and/or Fiberglass Concrete or OSB Compositions, Trusses, Floor, Ceiling, and Wall Panels, 4 to 10 ft. Wide by 2 to 80 ft. Long, also New Component Connecting Fasteners, also Concrete and Asphalt Roofing Materials, Rolls and Sections, Poured or Pressed Composite Mobile Homes, Single and Double Wide, also Dimensional Building Materials including Flooring, Siding, and Framing, also Poured or Pressed Sheds, Doors, Windows, Furniture and Cabinets, also related Equipment including a Wire Pulling Rack System, Gantry Crane Mounted on a Truck, Rail Car, or Semi Trailer, with Telescoping Mast and Boom, Elevating Boom, Hydraulic Stabilizers, Pumice Concrete Composite Mixtures and Usages, also a Crane for Rolled Roofing Material Delivery and one for Tree Service and Selective Cut Cellulosic Building Materials Harvesting.

Claimed is the invention of a new system of factory and site built complete quick erect construction using either concrete or pressed wood for residential homes and small commercial buildings. The system is comprised of the following components;

(a) Economical factory molded concrete composite road and rail transportable sectional residential buildings and small commercial buildings including floor, wall, ceiling, roof slabs, and foundation trusses roofs and floors.
(b) The use of the following materials for the potential construction of panels, trusses, beams, studs, and footers and foundation walls, including;
fiberglass strands and mats, nylon strands, sand, roofing stone size granules, pea size crushed stone, Styrofoam bead, Type M Portland cement, concrete mesh wire, concrete re-bars, nylon coated wire, re-bars, and wood splinters mechanically processed.
(c) Slab on site construction tilt up construction method for houses and small commercial buildings and the right to restrict or deny the usage of this method for commercial use of all of the inventions pertaining to concrete or concrete composite construction contained in this non-provisional filing.
(d) Residential and small commercial full span factory pre-cast steel reinforced concrete composite floors in new configurations as shown in FIG. 1.
(e) Pre-cast concrete composite injection molded or molded panels for floors with (small or) large insulation spaces for imbedded Styrofoam or fiberglass installed after mold insert removal as shown in FIG. 1, items A, B, C, G through G-7, H through H-2, J and J-1, and I through I-2, also FIG. 2, items I through I-4.
(f) Radius corner concrete composite floor panels for added strength as shown in FIG. 1, item a-1.
(g) Double thickness concrete main beams, side beams, and ends, for high panel strength during crane lifting as shown in FIG. 1, items A-2 and C-2.
(h) Factory installed ceramic tiles and factory stamped imitation floor tiles, molded or injection molded, or stamped, all-in-one or installed after erection construction at the time of concrete composite pouring of entire panel as shown in FIG. 1, item B-1.
(i) Ledged floor panels for truss setting as shown in FIG. 1, item C-1.
(j) Pre-cast concrete composite injection molded panels with concrete mesh reinforcement wire with various spacing and wire thicknesses depending on span length as shown in FIG. 1, item F-1.
(k) Tapered triple beams for all panels, roof, floor, and ceiling, with material saving weight lightening holes as shown in FIG. 1, item C-2, extendable precast concrete beams as needed for additional weight bearing as shown in FIG. 1, item C-3.
(l) Pre-cast concrete composite injection molded pressed or poured panels with or without pre-formed ledges for weight bearing support on roof or floor trusses as shown in FIG. 1, item F-4.
(m) Insulated cores for pre-cast concrete composite injection molded panels filled with injected solidified in place Styrofoam, loose fill bead Styrofoam, or loose filled fiberglass, as shown in FIG. 1, items g-1 and H-1.
(n) Residential or small commercial stem wall and foundation concrete composite flooring panels as shown in FIG. 2, items A, C, B-2, and B-3.
(o) Semi trucked full length floor panels for use with or without floor trusses, factory pre-cast concrete composite for houses and small commercial buildings and the combination of end-to-end extensions past 48 ft. long plus in additional sections for large custom homes as shown in FIG. 2, items A-1 and C-3.
(p) Factory pre-cast concrete composite footers as shown in FIG. 2, items b-1, b-4, B-3, B-5, B-6, B-9, D-4, G, G-1, and G-2.
(q) Lightening holes in concrete footers as shown in FIG. 2, item B-1.
(r) Concrete composite roof and floor trusses used in conjunction with factory concrete composite floor and wall sections as shown in FIG. 2, items B-2 and D-7, FIG. 3, item E, FIG. 5, item K, and FIG. 7, item A.
(s) Combination of stem wall and flared tapered footer, poured all-in-one shown as items B-5, Styrofoam encased insulated or fiberglass insulated with one side attached panels as shown in FIG. 2, items B-3, B-5, B-6, D-6, and F.
(t) Solid pre-cast footers, also shown in FIG. 2, item D-4.
if FIG. 2 (D-4).
(u) Hollow core insulated footer as shown FIG. 2, items B-3 and F.
(v) Combination footer and stem wall factory pre-cast all-in-one as shown in FIG. 2, item B-5.
(w) Round lightening holed concrete composite footers or walls with horizontal or vertical circular insulation cavities, also shown in FIG. 3, items D and E, FIG. 2, item D-2, and FIG. 4, items F, G, AND H, Also claimed is the invention of gravel beds under walls with plastic tiles for foundation drainage including full height basement walls as shown in FIG. 2, item B-6.
(x) 6A limestone gravel for footer beds used in conjunction with pre-cast flared footers and pre-cast footers for easy leveling of these items as show in FIG. 2, item B-8.
(y) 4A or 6A Thin Crushed Limestone Footer Base, 4″ Thick Racked Level
(z) Concrete composite factory pre-cast roof panels for small commercial buildings as shown in FIG. 5, items A and K-1.
Full length roof panels, factory pre-cast concrete composite for houses and small commercial buildings and the combination of end-to-end extensions past 48 ft. long for large custom homes as shown in FIG. 5, items A and K-1.
(a-a) Prefabricated footer and slab method of construction as shown in FIG. 2, item D.
(a-b) Factory pre-cast concrete composite wall sections with integrated footer as shown in FIG. 2, item D-2.
(a-c) Factory pre-cast concrete composite insulated welded wire reinforced ceiling panels as shown in FIG. 5, items A, H through H-3, I through I-3, L, M through M-1, and K-1.
(a-d) Center floor weight bearing footers for reduced thickness factory pre-cast paneled as shown in FIG. 2, item D-4.
(a-e) Reduced thickness factory pre-cast panels used in the no-crawl-space construction method as shown in FIG. 2, item D-5.
(a-f) Concrete composite stem walls as shown in FIG. 2, item F.
(a-g) One piece factory injection molded pre-cast concrete composite walls with multiple choice interior/exterior textures as shown in FIG. 3, item A.
(a-h) 8 ft. high and custom upscale residential 9 ft. high pre-cast factory trucked in concrete composite walls as shown in FIG. 3, item A.
(a-i) Pre-cast single piece wall sections as shown in FIG. 3, item A.
(a-j) Two or three story buildings of the same construction as described in this patent application.
(a-k) Shake shingle siding constructed of all presently available materials and those materials contained in this patent application and shown in FIG. 3, item A-4.
(a-l) A-2 claimed is the invention of all-in-one formed concrete walls with exterior and interior molded or stamped textures as shown in FIG. 3, items A-1 through A-4.
(a-m) Concrete Styrofoam encased factory pre-cast walls as shown in FIG. 3, item C-2.
(a-n) Rounded corner Styrofoam blocks for increased wall strength as shown in FIG. 3, C-2
(a-o) Triple beam integrated wall strengthening and six holed panel lifting method as shown in FIG. 3, item B.
(a-p) Wall molds, floor molds, roof panel molds, footer molds, truss molds, 4′×8′ panel molds, and concrete composite shingle molds as shown in FIG. 3, item D.
(a-q) Two story factory prefabricated concrete composite housing as shown in FIG. 3, item 3-E.
(a-r) Pre-cast factory molded concrete, OSB, or splinter OSB, fiberglass insulated walls, floors, roofs, trusses, ceilings, foundations, and footers, as shown in FIGS. 1 though 6, and FIG. 8.
(a-s) 4′ by 8′ or 9′ panels in various interior/exterior textures as shown in FIG. 4, item f-1, and items A, B, C, and D.
(a-t) Factory molded pre-cast one sided walls used in conjunction with various interior or exterior concrete composite 4′ by 8′ or 9′ panels for the other side as shown in FIG. 4, items F and G.
(a-u) Double sided 4′ by 8′ or 9′ panel walls used in conjunction with concrete, wood, composite OSB, or metal, wall studs as shown in FIG. 4, item H.
(a-v) Separate pre-cast factory built walls and footer with no flares as shown in FIG. 4, items J and I.
(a-w) Factory pre-cast concrete roof panels with truss setting ledges as shown in FIG. 5, items H, L, and.
(a-x) Factory concrete composite pre-cast panels molded or stamped with or without textured roofing material imitations as shown in FIG. 5, item b.
(a-y) Exterior waterproofing sealed concrete composite roof panels and factory or on-site applied sprays as described in FIG. 5, items B, D, and G.
(a-z) Integrated pre-cast strengthening studs concrete composite all-in-one injection molded or molded strength improving and panel lightening and insulation accommodating building panels as shown in this patent, FIG. 5, item C-1.
(b-a) Large sectional pre-cast concrete composite shingle sections and staggered interlock overlapping, 1′×4′, 2′×4′, and 4′×4′, rapid install sections as shown in FIG. 5, item D.
(b-b) Asphalt shingle sections and staggered interlock overlapping, double layered main body, 1′×4′, 2′×4′, and 4′×4′, all-in-one factory pre-assembled rapid install sections as shown in FIG. 5, item D-1.
(b-c) Individual piece splicing method of joining sections of factory asphalt and concrete composite roofing panels as shown by shingles marked with the letter P in FIG. 5, item E.
(b-d) Rolls of asphalt roof caps, 12″ to 18″ wide, as shown in this patent, FIG. 5, item F.
(b-e) Concrete composite shingles in various configurations including standard three tab shingles, with various textures such as;
rustic dimensional, cedar shake, slate, etc., also the conception of two to four through six tab shingles as shown in FIG. 5, item G.
(b-f) Lightened weight and thickness ceiling panels for ceiling applications as shown in FIG. 5, items H, K-2, and K-3.
(b-g) Cavity molded fiberglass insulation or pre-cast in place Styrofoam block insulation cavities poured or injection molded all-in-one ceiling panels as shown in FIG. 5, item L-1.
(b-h) Factory pre-cast ceiling or roof panels molded in place with embedded Styrofoam or fiberglass insulation as shown in FIG. 5, items H, I, L, M, and W, and FIG. 1, items J and J-1.
(b-i) Interlocking shingles in rolled form as described FIG. 5, item D-1, and roll sizes from 1′ to 25′ wide and lengths of up to 500′ as shown in FIG. 5, item J.
(b-j) Concrete composite vaulted ceiling trusses as shown in FIG. 13, items A, B, and C.
(b-k) 9 ft. 0 truss spacing used in conjunction with the new concrete composite construction system as an economical improvement to 24 inch spacing as shown in FIG. 5, item K-1.
(b-I) Pre-cast concrete composite injection molded panels for ceiling applications, upward mounted installation as shown in FIG. 5, item K-2.
(b-m) Pre-cast concrete composite injection molded panels for ceiling applications, downward mounted as shown in FIG. 5, item K-3.
(b-n) Pre-cast concrete composite injection molded panels for roof installation as shown in FIG. 5, items A, B, C, L, and M, and shown installed in FIG. 5, item K-1.
(b-o) Pre-cast concrete composite injection molded panels for ceiling applications and also the concept of lightened weight and thickness ceiling panels for ceiling applications as shown in FIG. 5, item H.
(b-p) Factory pre-cast all-in-one roof panels as shown in FIG. 5, items A, C, H, I, L, M, U, and V.
(b-q) Cavity molded fiberglass insulation or pre-cast in place Styrofoam block insulation cavities poured or injection molded all-in-one roof panels as shown in FIG. 5, item G.
(b-r) Circular core roof or ceiling panels with insulated core, loose fill or expanded polystyrene molded in place wet as shown in FIG. 5, item M.
(b-s) Concrete composite shingles with fiberglass core, mat, or strand, construction, 300 to 600 lbs. per sq. ft. as shown in FIG. 5, item N.
(b-t) Pre-cast pre-molded concrete composite shingle nail holes in the same configuration as presently used in shingle nailing patterns as shown in FIG. 5, item N-1.
(b-u) Asphalt seal
down strips used in conjunction with concrete composite shingles as shown in FIG. 5, item N-2.
(b-v) Interlocking single piece shingles as shown in FIG. 5, item P, used in conjunction with asphalt or concrete interlocking shingle panels as shown in FIG. 5, items B and E.
(b-w) Pre-bent asphalt or concrete composite ready made shingle caps as shown in FIG. 5, item Q.
(b-x) Ready made half shingles for drip edge roof completions in concrete composite and asphalt as shown FIG. 5, item R.
(b-y) Concrete composite deep piling residential and small commercial buildings for land slide and hurricane erosion resistance construction method as shown in FIG. 6.
(b-z) Reducing insurance cost resulting from loses incurred when land slides cause houses to become demolished as shown in FIG. 6.
(c-a) Concrete and concrete composite structural building components including beams, floor, ceiling, and roof, trusses and joists, and structural studs, with or without the addition of Styrofoam beads, air injection, and volcanic pumice as shown in FIG. 7.
(c-b) Concrete molded reinforced I-beam and non I-beam versions of floor, ceiling, and roof trusses and joists, and structural studs as shown in FIG. 7.
(c-c) Wiring and plumbing material molded lightening holes, with round holes the size of up to one third the material volume for the purpose of material saving and weight reduction as shown in FIG. 7.
(c-d) Concrete commercial and residential I-beams, studs, floor, ceiling, and roof trusses and joists, as shown in FIG. 7.
(c-e) Nylon coated cross checked steel reinforcement wire for concrete small and large construction members as shown in FIG. 7, items D and I.
(c-f) Thin walled, 1″ to 12″ thick, volcanic pumice high strength concrete mixtures containing all sizes of crushed lime stones (4A to 22A), fiberglass reinforcing fibers, sand, Type M cement, Styrofoam bead and blocks, and the usage of lightweight reinforcing wires or nylon cables as described in the Provisional Patent Application 61/148,135, FIG. 1 items K, L, and m.
(c-g) Ultra wide concrete composite trusses, 4-36″, as shown in FIG. 8, items j and n, FIG. 5, item k, and FIG. 2, items b-2,d-6, e, and f.
(c-h) Ultra wide wood composite trusses, 4-36″, as shown in FIG. 8, items j and n, FIG. 5, item k, and FIG. 2, items b-2,d-6, e, and f.
(c-i) The usage of these volcanic pumice and concrete mixtures in residential and commercial construction.
(c-j) The usage of composite volcanic pumice concrete mixtures in all products listed in the previous Provisional Patent Application 61/218,595 Concrete Composite Fencing Systems and the previous Provisional Patent Application 61/481,135 FIGS. 1, 2, and 3, and products in this Original Provisional Patent Application 61/157,328, All Figures.
(c-k) The usage of volcanic pumice mixtures to produce light weight concrete.
(c-l) The usage of composite volcanic pumice mixtures as an insulated concrete material.
(c-m) The usage of composite volcanic pumice mixtures is the construction of residential and commercial buildings.
(c-n) Concrete wedge block fastener, single precast molded with the wall or double sided insertable block for insert connecting together vertical concrete walls as shown in FIG. 2, item d-7. 45 degree angle wall and foundation section ends connection method as shown in FIG. 2, d-8. Bolt holes 45 degree angled for high strength connection at corner with molded recessed counter sinks at both ends, also used with new fasteners shown in FIG. 3, items F, I, and H.
(c-o) The usage of roof sections, FIG. 5, item a, with rolled roofing products shown in FIG. 18, items p, a, and n. Also, described and shown in FIGS. 3, 4, and 5, the non-provisional patent filing Ser. No. 12/633,049.
(c-p) Panel lifting and mold breaking fasteners shown in FIG. 1, item A-6. Also, barrel type fasteners shown in FIG. 1, items A-8, C-6, D-1, and F-1. Also, main column and beam fasteners as shown in FIG. 1, A-5.
(c-q) Material saving and weight reduction holes, also used for plumbing and electrical access, shown in FIG. 1, item C-2, also FIG. 2, item H, and FIG. 5, item C-2.
(c-r) Tongue and groove panel seams with sealant in bottom shown in FIG. 1, item C-4.
(c-s) Built-in span lengthener beam for floor and ceiling panels as shown in FIG. 1, item G-6, FIG. 2, items J-1 and L-1, and FIG. 5, items H-1, I-1, and V.
(c-t) Ledge strengthening galvanized reinforcing wire as shown in FIG. 1, item G-5.
(c-u) Fastener attached panel insulation cover and firewall for more combustible main panel, drywall or cast concrete as shown in FIG. 1, item G3, also shown in FIG. 4, items F-1 and H-1.
(c-v) Bolt together panels as shown in FIG. 1, items G-4 and C-5, also show in FIG. 2, items J-1 and L-1, and FIG. 5, items H-1 and 1-1.
(c-w) Complete panel insulating aggregate mixtures including vermiculite, pumice, and/or Styrofoam beads or small peanuts as shown in FIG. 1, items J, J-1, and J-2.
(c-x) Panel and I-Beam Flooring System as described in FIG. 2, items I and A-3.
(c-y) Poured or pressed building walls with built-up truss weight bearing members as shown in FIG. 3, items A, B, and C, and FIG. 1, item A-5, and FIG. 4, items E and F.
(c-z) Foundation wall or structural wall weight spreading reinforcement angular and vertical beam and molded-in footer plate as shown in FIG. 3, items F-3, F-4, and F-5.
(b-a) Plumbing and electrical installation using insulation impressing for pre-poured walls with mold faced pre-mounted boxes and Styrofoam blocks for wiring and plumbing through the wall edge termination as described in FIG. 3, items A-5 through A-9.
(b-b) New fasteners, greased or oiled, coarse ACME thread, hot metal, nylon, or high strength concrete encased reinforced rebar as shown in FIG. 3, items F-1, F-3, I, I-1, G, H, J, J-1, K, and L.
(b-c) Textured Interior/Exterior Panels, poured or stamped masonry or pressed OSB, 2′×8′ and 4′×4′, as shown in FIG. 4, items D and A-2
(b-d) Pre-drilled or molded panel edge fastener attachment holes and/or 16″ or 24″ O.C. vertical stud attachment holes for all size building material panel sheet goods an example is shown in FIG. 4, items D-1 and A-4.
(b-e) Tongue and Groove and Weather Seal Angling Tongue and Groove Siding Building Panels including raised textured masonry and pressed OSB as shown in FIG. 4, item F-1.
(b-f) Seam hiding matching pattern textures individual concrete composite or OSB pieces as shown in FIG. 4, items A-4 and A-6, also shown in FIG. 5, item P.
(b-g) Interlocking Siding Panels OSB or Concrete Composite as shown in FIG. 4, item A-7.
(b-h) Molded Wall Panels with studs and weight bearing column molded in as shown in FIG. 4, item f.
(b-i) Molded Panels with studs and exterior molded raised finishes compatible with pre-drilled panels as shown in FIG. 4, items G-1 through G-4.
(b-j) Molded Dimensional Lumber or Conventional Lumber used in conjunction with exterior and interior masonry textured panels as shown in FIG. 4, item H-2.
(b-k) Concrete Main I-Beam with connecting fasteners used in conjunction with building trusses and for lateral truss racking strength as shown in FIG. 5, item K-5.
(b-l) Trusses with material saving weight reduction holes and I-Beam strength wrapping as shown in FIG. 5, item K.
(b-m) I-Beam or Solid Beam with top side angle panel ledges molded in and pre-drilled fastener holes for roof panels as shown in FIG. 5, items K-4 and O-1.
(b-n) Concrete or OSB Composite Fastener Connection Methods for Panel to Beam, Truss to Wall Panel, Truss to Beam, Truss to Roof Panel, Beam to Roof Panel, and Wall Panel to Roof Panel, as shown in FIG. 5, items C-7, K-5, K-7, 5-1, S-2, and O-1.
(b-o) Beam to Roof Panel Connection Method as shown in FIG. 5, items S-3 and O.
(b-p) Panel Truss Panel through Pinned Connection Method as shown in FIG. 5, items M-2 and M-3.
(b-q) Multiple Ganged Two Sided Molds and Wire Spools as shown in FIG. 12, items D-5, D-6, and D-7.
(b-r) Multiple Mold Gang Fastener Bars as shown in FIG. 5, item D-8.
(b-s) Wall Panel Lifting Methods as shown in FIG. 12, item D-4, and G-6.
(b-t) Single Wide and Double Wide Concrete or OSB Composite Mobil Homes including Low Pitched Single Wide Roofs as shown in FIG. 13, items A through E.
(b-u) Split Structural I-Beam made of Concrete or OSB Composite as shown in FIG. 13, items A-4 and B-1.
(b-v) Back Hoe attachment for Chain Saw as shown in FIG. 19, items A and B.

128 more elements

Building system, concrete or OSB, pour molded or pressed molded, composite panels, trusses, and products, with engineering methods and fasteners, and related transportation, erection, and materials processing equipment

Life of this patent

Building system, concrete or OSB, pour molded or pressed molded, composite panels, trusses, and products, with engineering methods and fasteners, and related transportation, erection, and materials processing equipment

Life of this patent

Abstract

Claims3