Element based foam and concrete wall construction and method and apparatus therefor

Abstract

A element based wall construction, process of modular construction and apparatus for constructing structures of spaced concrete cylinders and beams and foam insulating blocks. The wall construction includes spaced, vertical concrete cylinders interconnected by horizontal concrete beams, reinforced by centrally located reinforcing bars, with a pilaster projecting inwardly beyond the cylinders and beams to support roof and floor joists or trusses, and insulating foam blocks occupying the spaces between cylinders and beams and projecting outwardly beyond the cylinders and beams to define channels for mounting plumbing and electrical conduits and wiring beneath the sheet rock or siding which abuts the foam block surfaces. The process includes the construction of concrete column and beam forming assemblies interspersed with insulated blocks to form a complete wall structure for a building with exposed pilaster channels at each floor and roof level connected to the beam and column defining apertures, stabilizing the structure, and substantially continuously pouring concrete into the channels to create a unitary wall structure. Floor and roof joist fasteners are inserted prior to concrete pour or into the partially cured concrete of the pilasters. The floor and roof joists are mounted to the fastener after the concrete sets. Plastic anchors to mount sheet rock and siding are inserted through the insulating blocks into cylindrical apertures therein, before the concrete pour, and are locked into the hardened concrete cylinders. Plumbing and electrical wiring and junction boxes are fastened to the beam defining channel members before the concrete pour and then are locked in place by the cured concrete beams.

Dependencies are inferred from the claim text.