Modular construction system
OwnerGordon G. Lainginventor
Life of this patent
Estimating the term…
Abstract
A modular construction system utilizes building components or panels formed of high strength plasticized concrete. Panels are formed with two or more linear peripheral edges fitted with mortises. FRP pultruded tenons are used to connect aligned mortises for adjacent panels. Walls, crown beams and roof panels can be so formed and assembled. Hollow corrugated panels are suitable for forming beams and interior partitions. Beams can be rested on regularly spaced piles and then floor panels on the beams, walls on the floor panels, crown beams on the walls and roof panels on the crown beams, buildings can be erected with a minimum of tools or specialized knowledge. The resulting structure is substantially impervious to environmental hazards, particularly relevant in more primitive locations.
Claims18
A system of modular concrete construction for forming a roofed and walled structure comprising:
- a plurality of first lightweight composite concrete building components having at least a top linear peripheral edge formed with a linear dovetailed fitting mortise for forming wall panels;
- a plurality of second lightweight composite concrete building components which have a greater lateral dimension than height, wherein at least top and bottom linear peripheral edges are formed with linear dovetailed mortises for forming crown beams;
- a plurality of third lightweight composite concrete building components having at least a bottom linear peripheral edge formed with linear dovetailed fitting mortises for forming roof panels;
- a plurality of flared tenons for fitting in the mortises, so that when the mortises of two or more building components are aligned, the components are joined by inserting the flared tenons along the peripheral edges and into the aligned fitting mortises;
- and
- a plurality of crown beams having top and bottom edges, joined end to end atop the wall and inserting tenons to join the bottom edges of the crown beams to the top edges of the wall panels and below the roof panels by inserting tenons to join the top edges of the crown beams to the bottom edges of the roof panels.
A method of modular concrete construction for forming a roofed and walled structure comprising the steps of:
- providing a plurality of first lightweight composite concrete building components having at least a top linear peripheral edge formed with a linear dovetailed fitting mortise for forming wall panels;
- providing a plurality of second lightweight composite concrete building components which have a greater lateral dimension than height, wherein at least top and bottom linear peripheral edges are formed with linear dovetailed mortises for forming crown beams;
- providing a plurality of third lightweight composite concrete building components having at least a bottom linear peripheral edge formed with linear dovetailed fitting mortises for forming roof panels;
- assembling the plurality of wall panels by aligning two adjacent wall panels and inserting tenons into adjacent fitting mortises to join adjacent wall panels and form a wall;
- assembling the plurality of crown beams by joining them end to end atop the wall and inserting tenons to join the bottom edges of the crown beams to top edges of the wall panels;
- and
- assembling the plurality of roof panels atop the crown beam by aligning two adjacent roof panels and inserting tenons to join the bottom of the roof panels to the top edges of the crown beams.
A method of modular concrete construction for forming a roofed structure comprising:
- providing a plurality of first lightweight composite concrete building components having at least a top linear peripheral edge formed with a linear dovetailed fitting mortise for forming wall panels;
- providing a plurality of second lightweight composite concrete building components which have a greater lateral dimension than height, wherein at least top and bottom linear peripheral edges are formed with linear dovetailed mortises for forming crown beams;
- providing a plurality of third lightweight composite concrete building components having at least a bottom linear peripheral edge formed with linear dovetailed fitting mortises for forming roof panels;
- assembling the plurality of wall panels by aligning two adjacent wall panels and inserting tenons into adjacent fitting mortises to join adjacent wall panels and form a wall;
- assembling the plurality of roof panels by aligning two adjacent roof panels and inserting tenons to join adjacent roof panels and form a roof;
- and
- installing the crown beams end to end intermediate the wall and roof for absorbing roof loading and transferring the loading vertically into the wall.
A method of modular concrete construction comprising the steps of:
- forming lightweight composite concrete building components having one or more linear peripheral edges formed with linear dovetailed fitting mortises, by
- forming first and second sheets of a lightweight composite concrete;
- forming a third corrugated sheet of a lightweight composite concrete;
- sandwiching the third sheet between the first and second sheets to form a corrugated panel having at least two opposing linear peripheral edges;
- inserting an FRP extrusion into at least two linear peripheral edges for forming a mortise;
- providing one or more flaring tenons;
- aligning two adjacent building components with aligned fitting mortises;
- and
- joining the aligned panels by inserting one or more of the flaring tenons along the peripheral edge and into the aligned fitting mortises.
Dependencies are inferred from the claim text.