Apparatus and process for casting large concrete boxes

A method of forming a concrete integral box shaped module having four rectangular side walls, comprising the steps of:

• constructing a fixed box form having four vertical rectangular sides with vertical corner spaces formed between the four vertical sides;
• positioning top trays extending out from top edges of the four rectangular sides, and bottom trays from bottom edges of the four rectangular sides;
• placing corner fillers at the vertical corner spaces to stabilize the vertical sides and block the corner spaces;
• laying reinforcing steel mesh in the bottom trays and against the four vertical sides;
• filling the bottom trays with concrete to form lower lips extending out from bottom edges of the side walls of the module;
• spraying concrete on the reinforcing steel mesh and rebar on the four vertical sides to form the side walls of the module;
• filling the top trays with concrete to form upper lips extending out from top edges of the side walls of the module;
• steaming the module on the box form to set the concrete;
• removing the top trays from the module;
• and
• removing the module from the form by lifting and at the same time jacking up the lower lips of the module to separate from the bottom trays with the corner fillers permitting limited relative movement of the vertical sides of the form to assist in removal of the module from the form.

A box form for forming a concrete integral box shaped module having four rectangular side walls, the box form comprising:

• four fixed vertical rectangular sides with a top horizontal surface forming a box shape with vertical gaps between adjacent rectangular sides forming vertical corner spaces;
• bottom trays extending out from bottom edges of the four rectangular sides, the bottom trays having removable plates therein for positioning lifting jacks thereunder;
• removable corner fillers positioned at the vertical corner spaces to stabilize the vertical sides and block the corner spaces while still permitting limited relative movement of the vertical sides on removal of the module from the form to facilitate separation of the module and form;
• and
• removable top trays connectable to top edges of the four rectangular sides.