3-D construction modules

A 3D construction module comprising:

• a) First and second vertically upstanding, spaced apart panels oriented generally longitudinally;
• b) First and second mesh layers oriented generally transversely and longitudinally, each of said first and second mesh layer comprising at least one rod member mounted to each of said first and second panels, said first and second mesh layers being vertically spaced from each other;
• said at least one rod member of said first mesh layer configured to co-operate with said at least one rod member of said second mesh layer to form a first horizontally projected retention cell to restrict translation of a vertical reinforcement bar held in said retention cell between said first and second mesh layers;
• c) a vertical reinforcement bar held in said retention cell;
• whereby said retention cell forms a generally vertically oriented opening for receiving said vertical reinforcement member, said retention cell restricts translation movement longitudinally of a vertical reinforcement member held in said retention cell.

A 3D construction module comprising:

• a) First and second vertically upstanding, spaced apart panels oriented generally longitudinally;
• b) First and second mesh layers oriented generally transversely and longitudinally, each of said first and second mesh layer comprising at least one rod member oriented generally transversely and mounted to each of said first and second panels, said first and second mesh layers being vertically spaced from each other;
• said at least one rod member of said first mesh layer configured to co-operate with said at least one rod member of said second mesh layer to form a first horizontally projected retention cell to restrict translation of vertical reinforcement bars held in said retention cell between said first and second mesh layers;
• c) a first vertical reinforcement bar held in said first retention cell;
• whereby said first cell forms a first generally vertically oriented opening for receiving respectively, said first vertical reinforcement member, said first retention cell restricting translation movement longitudinally and transversely of said first vertical reinforcement member held in said retention cell;
• d) a horizontal reinforcement mesh comprising first and second reinforcement bars oriented generally longitudinally, said first and second horizontal reinforcement bars being interconnected by at least one transverse connecting rod member, said horizontal reinforcement mesh being received between said first and second panels with said first and second horizontal reinforcement bars being oriented generally longitudinally and said first horizontal reinforcement bar being in abutment with said first vertical reinforcement bar so as to tend to push said first vertical reinforcement bar transversely outward toward said first panel.

A stopper member comprising:

• a cylindrical body portion having a first end and a second end, and having a first axial passageway open from said first end and said second end;
• a first flange member formed on said body at said first end;
• a second flange member formed on said body at said second end
• a second body portion joined to said first body portion at said second end, said second body portion having a second axial passageway that is narrower than said first axial passageway, said second body portion having a first generally cylindrical portion adjoining said second flange member, and a truncated conical flange portion, said truncated conical flange portion and said second flange member providing a cavity therebetween for holding at least one rod member therebetween.

A method of fabricating a 3D construction module comprising:

• a) providing a vertically upstanding panel oriented generally longitudinally;
• b) securing first and second mesh layers to said panel such that they are oriented generally transversely and longitudinally, each of said first and second mesh layers comprising at least one rod member mounted to said panel, and said first and second mesh layers being arranged in vertically spaced relation to each other;
• c) arranging said at least one rod member of said first mesh layer and said at least one rod member of said second mesh layer to form a first horizontally projected retention cell to restrict translation of a bar held in said retention cell between said first and second mesh layers;
• whereby said first retention cell forms a generally vertically oriented opening for receiving a vertical reinforcement member and said retention cell restricts translation movement longitudinally and transversely of a vertical reinforcement member held in said retention cell.

A stopper member in combination with a connector:

• said connector having a leg portion adapted to connect to a rod member;
• said stopper member comprising:
• a body portion having a first end and a second end, and having a first axial passageway open from said first end and said second end;
• a second body portion having a third end and a fourth end, said second body portion joined at said third end to said first body portion at said second end of said first body portion, said second body portion having a second axial passageway extending between said third end and said fourth end, that is narrower than said first axial passageway, said second axial passageway being in communication with said first axial passageway from said third end to said second end,
• said leg portion of said connector receivable into said first axial passageway of first body portion of said stopper at said first end to engage an end of a rod member receivable in said second axial passageway and extending from said fourth end, past said third end and said second end into said first axial cavity;
• said connector and said stopper member adapted to hold a panel member and thereby connect said rod member to said panel member.

A method of forming a construction element such as wall comprising:

• a) prefabricating first and second construction modules, each of said modules comprising a pair of spaced apart panels oriented longitudinally, said pair of panels being interconnected by at least one mesh layer between said panels;
• b) installing said first and second construction modules in longitudinal alignment;
• c) installing vertical reinforcement in said first and second construction modules;
• d) installing horizontal reinforcement in said first and second construction modules;
• and
• e) filling said first and second construction modules with unhardened concrete.

A panel for use in a 3D construction module, said panel comprising:

• a body with a thickness and said body having opposite generally vertically oriented side edge faces;
• a plurality of spaced pre-formed openings passing generally transversely through said body, said openings arranged in an arrangement of first, second, third and fourth generally longitudinally oriented and vertically spaced rows of openings, each of said first row including at least two longitudinally spaced openings, said first row, said second row, said third row and said fourth row being successively vertically spaced and stacked in relation to each other with said second row positioned vertically between said first row and said third row;
• wherein consecutive openings of said first row and consecutive openings in said third row are generally aligned respectively along a plurality of first generally vertically oriented lines;
• and wherein consecutive openings of said second row and consecutive openings in said fourth row are generally aligned respectively along a plurality of second generally vertically oriented line that is spaced from, but generally parallel to, said first lines;
• wherein generally said plurality of openings of said first row are not vertically aligned with any of said plurality of openings of said second row or said fourth row;
• and
• wherein generally said plurality of openings of said third row are not vertically aligned with any of said plurality of openings of said second row or said fourth row;
• and wherein said first and second rows of openings are positioned in a plurality of corner locations defining a first row of adjacent parallelograms, and wherein said second and third rows of openings are positioned in a plurality of corner locations defining a second row of adjacent parallelograms positioned beneath said first row of adjacent parallelograms, said arrangement permitting the use of said panel in said form system so as to provide longitudinal spacing between said first and second lines so that a vertical rod can be received between generally transverse oriented rods mounted in each of said openings.

A method for interconnecting first and second panels in longitudinal, upstanding and abutting alignment, each of said first and second panels comprising a pair of opposed side end surfaces, each of said side end surfaces having an elongated groove formed therein extending along at least a portion of the length of said side end surfaces, said grooves being configured to receive and hold a separate elongated plate member along at least a portion of the length thereof, said plate and said grooves cooperating to provide a friction force between them to hold the first and second panels in place when subjected to a force exerted against the first and second panels by poured concrete, said method comprising:

• a) inserting a first longitudinal strip of said plate member longitudinally into said groove of said first panel;
• b) moving said second panel and second panel towards each other such that an opposed strip of said plate member is received longitudinally into said groove of said second panel, said grooves and said plate member being configured such that said first panel and said second panel can be brought into abutment with each other at said side surfaces, wherein said first and second panels have outward facing longitudinally extending surfaces and wherein said plate member is configured with a wedge surface portion on at least one side, and wherein adjacent side portions of each of said first panel and said second panel of said adjacent said grooves are deformed outwardly when said plate member is inserted in said grooves, said side portions are displaced outwards by said wedge surface portion to provide face to face mating alignment of said side portions of said first and second panels.

A 3D construction module comprising:

• a) First and second vertically upstanding, spaced apart panels oriented generally longitudinally;
• b) First and second mesh layers oriented generally transversely and longitudinally, each of said first and second mesh layers comprising at least one rod member oriented generally transversely and being mounted to each of said first and second panels, said first and second mesh layers being vertically spaced from each other, said at least one rod member of said first mesh layer being longitudinally offset relative to said at least one rod member of said second mesh layer, said first and second mesh layers further each comprising first and second longitudinal rod members oriented generally longitudinally;
• said at least one rod member of said first mesh layer configured to co-operate with said at least one rod member of said second mesh layer to form a first horizontally projected retention cell to restrict longitudinal translation of vertical reinforcement bars held in said retention cell;
• c) a first vertical reinforcement bar held, respectively, in said retention cell, translation movement transversely of said vertical reinforcement bar being restricted by said first longitudinal rod member of said first mesh layer.