Method for fabricating six-sided concrete modules
AssigneeStrong Built Structures, Inc.
InventorJeffery Alan Manning
Life of this patent
Estimating the term…
Abstract
A method to create a precast concrete module includes: pouring the foundation; placing a welded wire mesh reinforced polystyrene panel into a wet mix; allowing the mix to partially set up, and pouring the top of the slab; installing wall and roof panels and mechanically attaching them with welded wire mesh; installing electrical and plumbing prior to placing concrete forms; placing the forms and pouring concrete mix into the forms; and wrecking the forms and finishing out the module.
Claims20
A method of constructing an integrated six-sided concrete module comprising a floor, four walls, and a ceiling, the method comprising:
- setting a first set of concrete forms for forming the floor of the concrete module;
- partially forming the floor by pouring concrete to partially fill the concrete forms;
- submerging a floor panel and a first set of connectors into the partially formed floor;
- coupling wall panels and a second set of connectors to the floor panel;
- pouring concrete to completely fill the first set of concrete forms to form the floor of the concrete module;
- coupling a ceiling panel and a third set of connectors to the wall panels;
- removing the first set of concrete forms;
- setting a second set of concrete forms for forming the walls and the ceiling of the concrete module;
- pouring concrete to complete the walls and the ceiling of the concrete module;
- and
- after the poured concrete hardens, removing the second set of concrete forms to reveal the finished six-sided concrete module,
- wherein the floor panel, the wall panels, and the ceiling panel each comprise a welded wire mesh foam panel, and wherein pouring concrete comprises pouring concrete directly over at least one of said welded wire mesh panels.
A method of constructing an integrated six-sided concrete module comprising a floor, four walls, and a ceiling inside an existing structure, the method comprising:
- coupling rebar dowels into an existing floor slab;
- attaching wall panels to the rebar dowels;
- attaching a ceiling panel to the wall panels;
- setting interior concrete forms for forming the walls and the ceiling;
- pouring concrete to complete the walls and the ceiling of the concrete module;
- and
- after the poured concrete hardens, removing the set of interior concrete forms to reveal the finished six-sided concrete module inside the existing structure,
- wherein the wall panels, and the ceiling panel each comprise a welded wire mesh foam panel, and wherein pouring concrete comprises pouring concrete directly over at least one of said welded wire mesh panels.
Dependencies are inferred from the claim text.