Methods of manufacturing and constructing a habitable, cementitious structure

Abstract

Invention is a synergistic whole comprised of processes, machines, articles of manufacture and compositions of matter required to construct a habitable structure comprised of a cementitious product, in this example autoclaved aerated concrete (“AAC”), formed in unique blocks, panels and beams, resulting in an extremely environmentally friendly habitable dwelling, residential or commercial, which, due to the resultant synergy of embodiments, when compared to a similar structure employing prior art and/or current industry's standard materials and methods of construction, is structurally superior and simultaneously yields substantial savings in labor, time and costs.

1 . In a method of constructing multi-sided, habitable dwellings principally from pre-cut sections of a cementitious material for building up from a foundation, said method comprising the following steps to form a wall: 
 a.) selecting a discontinuous first course of blocks for cementing on said foundation, where said first course blocks include at least a longitudinal slot, with said slots of adjacent blocks aligned;    b.) said first course is having vertically oriented blocks of predetermined size with length of “X” so that top of said block closely equals height of door opening so that a horizontal plane is formed along top of wall section; and    c.) adding horizontally aligned beams on top of said primary course, where a planar top surface is provided, and    d.) where openings in said wall are located a on at least a 1′ center course and a predetermined structural component which is architecturally finished on three sides borders said opening.    
     
     
         2 . The method according to  claim 1 , wherein said aligned longitudinal slots are aligned to define an internal continuous slot for receiving utilities including the further step of concealing the longitudinal slot by covering with subsequent course of block.  
     
     
         3 . The method according to  claim 1 , including the step of inserting an arcuate configured insert into a receptive longitudinal slot at any angled junction whereby to facilitate feeding of said utility wiring through said receptive slots.  
     
     
         4 . The method according to  claim 2 , including the step of providing openings in communication with said continuous slot to house utility electrical wiring outlets for access to said first living level.  
     
     
         5 . The method according to  claim 1 , wherein plural curved cementitious blocks are utilized in said construction, and said curved blocks are fabricated into predetermined curve shape prior to cementitious material being in final cured state.  
     
     
         6 . The method according to  claim 1 , including the step of using manufacturing blocks with plural internal voids which when stacked vertically align to continuously communicate from the base through the upper most block so that the desired temperature communicated in voids is able to effect block's material and offset negative effects of exterior temperature.  
     
     
         7 . The method according to  claim 1 , wherein said final course of cementitious beams has an enclosed longitudinal void which can house air duct system so that when said beams are joined a resultant continuous duct system is developed, and openings are made through said beam material into said air duct system as required for living space.  
     
     
         8 . The method according to  claim 1 , when completed said wall is to support a roof system, wherein an uppermost course of blocks includes a top angled planar surface to define a roof pitch for securing a roof system thereto so that there is no gap between angled roof system and top of said uppermost course of blocks and the interior face may be architecturally modified for finished appearance.  
     
     
         9 . The method according to  claim 1 , including the step of overlaying and spanning said final course of beams with predetermined floor panels which have a slot manufactured into said panel, with said slots of adjacent panels aligned, whereby placing rebar and mortar into slot in effect slot becomes a bond/ring beam which is integrated into said floor panel, and 
 a.) at least an upper level of embedded steel reinforcing stops shorter of panel end which rests on said wall than any other embedded reinforcing so that slot can be manufactured without interference from said embedded reinforcing,    c.) said panel end being allowed to be flush with exterior wall face and still meet construction requirement of bond/ring beam.    
     
     
         10 . The method according to  claim 8 , including adding a stair system to join said multiple living levels, where said stair system is comprised of steps of predetermined cementitious material which require no fasteners nor mortar, and 
 a.) which said steps have a slot manufactured into at least one end, which slot corresponds to desired angle of stair's run, with said slots of adjacent steps aligned, and    b.) wall also has a corresponding said slot so that when a guide mechanism which length runs from near lower living level to short of upper floor level is inserted into wall slot, and    c.) as individual steps are placed into gap between upper end of said guide and upper living level and said slot on step is positioned onto said guide mechanism, the step is then lowered to rest on floor and as process progresses the previous step until a stair system connecting levels results.    
     
     
         11 . The method according to  claim 9 , including the steps of securing a prefabricated, predetermined elongated shapes similarly shaped to a beam of cementitious product which may be reinforced with steel and which can contain a continuous internal void extending from end to end and is open at each end, said beam to secured to said angled planar surface of cementitious material by notching at least one part of either said beam and planar surface so that scarfed joint engage and said beam and planar surface are permanently fastened using only mortar and a metal helical device.  
     
     
         12 . The method according to  claim 11 , wherein said beam system includes plural said beam members which connect to each other so that a structural support system results from following steps: 
 a.) said beams have corresponding notched ends which match for close to flush fit, and    b.) said beams have a longitudinal cavity into which reinforcing and cement can be inserted, and    c.) said longitudinal cavity aligns with other beam's said cavity so that reinforcing and cement inserted flows through individual beams and thereby make one monolithic system.    
     
     
         13 . The method according to  claim 12 , wherein said beam system is comprised of 
 a.) have ends to flush fit, and    b.) a predetermined structural material, and    c.) a permanently attached parallel section of a softer cementitious material for receiving fasteners.    
     
     
         14 . The method according to  claim 13 , including the further step of applying plural panels to said beam system, said method comprising the steps of: 
 a.) using fasteners which requires no pre-drilling yet to allow adhesive to be inserted into cavity formed by said fastening device, and    b.) said plural panels which are installed at an angle are held in desired position by fastening device while adhesive sets.    
     
     
         15 . The method according to  claim 14 , including the further step of applying cementitious roof panels comprised of exposed vertical face having a chamfer with at least one sharply reversing and upward angled groove which aligns with other said panels running parallel to the length of said roof face, said cementitious roof panels having reinforcing design modified so that at least one section of reinforcing stops shorter of panel end and/or side than other sections, which resultant area void of reinforcing allows panel to be modified by cutting a trough without interference.  
     
     
         16 . The method according to  claim 14 , including the further step of top surface face of said roof panels containing an engraved trough running at a downward angle and with said trough of adjacent said roof panels aligned so that moisture flows by force of gravity through said trough.  
     
     
         17 . The method according to  claim 15 , including the further step of overlaying said roof panels with a polyester/nylon mesh fabric featuring alternating sections of a tight mesh and a loose mesh.  
     
     
         18 . The method according to  claim 16 , including the step of applying an elastomeric material to said mesh fabric, where said elastomeric material penetrates only said loose sections to bond to said roof panels, such that an air cavity is created between said tight mesh and said roof panels, which predetermined said air channel is of sufficiency for vapor permeability of roof panel and runs unobstructed from lower starting position to near upper roof ridge where it exhausts.  
     
     
         19 . The method according to  claim 15 , including the step of applying a roofing material on habitable dwelling which is: waterproof, climate durable, chemical resistant, vapor permeable, high modulus of elasticity, durable, tintable for various colors, bonds well to cementitious material and can be continuously re-coated so material never requires removal.  
     
     
         20 . A dual operational fastening device for securing together cementitious materials, said fastening device comprising: 
 a.) shank member having an annular wall, a core with opening at first end for receiving material into which said fastening device is inserted, and between said first core and an adjacent wall portion a second core extending to an opening in second end into which an adhesive can be inserted, plural annular cut-out portions extending tangentially from said annular wall connecting to first said core, and plural longitudinal recesses in said annular wall connecting to said second core, and a helical thread arrangement about said annular wall; and,    b.) a broadened head member at first end of said shank member, where said head member includes means for removably securing a rotating hand tool and a void where thread becomes head and end of head does not connect to thread, said opening enabling fastener to counter sink.    
     
     
         21 . A fastening device according to  claim 19 , wherein there are plural sections of angled tangentical helical thread sections protruding from a shank, to form said helical thread arrangement, so that said thread sections assist the shank staying centered in hole and on course during insertion so that adhesive can flow around said thread sections and fill cavity between said shank and wall of material.  
     
     
         22 . The fastening device according to  claim 21 , wherein said helical thread sections comprise: 
 a.) thread sections wider at shank and narrowing toward outer end, and simultaneously thread sections are thicker at said shank and thinning toward the outer end, and,    b.) said sections are thinner at front leading edge and thicker at second following edge and front leading edge from said shank is shorter than back following edge.    
     
     
         23 . A fastening device wherein fastening device is comprised of: 
 a.) voluted solid or hollow shank extending into plural helical threads with very low number of revolutions around shank as it runs distance of shank from pointed first end head to broad second end, and    b.) first end with point which can be exploded from within by an item inserted into hollow shank from second broad end, and    c) said threads near first pointed end having openings in said thread so that material is caught in it and assists device's grip in material, and    d.) said second end having a broad head which can be hammered as means for removably securing said fastening device and said head also containing a slot for receiving the bit of a conventional screw driver for removing said fastening device, and    e.) said head on base houses prongs which crush cementitious material performing a countersink effect for said head while being inserted.    
     
     
         24 . The method according to  claim 2 , including the step of manufacturing curved blocks by a rounded mold inserted into current art pan, which rounded mold has predetermined arch and size compatible with desired product and cooperates with prior art pan mold through current industry manufacturing process.  
     
     
         25 . The method according to  claim 2 , including the step of manufacturing curved blocks while cementitious material is in “green stage” (still soft) a computer controlled mechanism with cutting wires directs said wires through said “green” cementitious material in a pattern which equates highest yield and least waste, which results in curved cementitious blocks prepared for curing.  
     
     
         26 . The method according to  claim 7  of manufacturing elongated voids in a material by inserting a conical shaped implement in such a manner that smaller end is imbedded in material and larger end is at exterior of material so that implement can be easily removed with minimal resistance, and 
 a.) two said conical pieces can be connected at smaller ends by having threaded male and female ends, and  
 b.) said conical insert can have an extending helical design so that when removed ridged indentations are in cementitious material to assist bonding when said elongated void is to be filled.  
 
     
     
         27 . Method according to  claim 20  which joins and simultaneously reinforces two pieces of materials in one step by adding liquid form of said material to said elongated cavity so when said liquid flows out of said openings in annular wall and bonds to material and sets it makes one monolithic, structurally reinforced piece from plural pieces of materials.  
     
     
         28 . Method according to  claim 1  by which a fire rated wall can have a door built of same cementitious material as wall.  
     
     
         29 . Method according to  claim 1  by which invented machines modify plumb surfaces of cementitious material by creating openings and architectural finishes using a template and guide system able to be employed on permanently positioned vertical pieces.  
     
     
         30 . Method according to  claim 1  using a cutting system on a vertical surface to create openings and architectural finishes by steps of 
 a) a male type rail system comprised of a bar attached to the surface which is to be modified set a predetermined distance from area to be modified,  
 c) which said predetermined distance of said rail corresponds to predetermined distance of a female, receptive type brace on tool, so  
 d) when said receptive brace is guided along said rail an accurate work is completed.  
 
     
     
         31 . Process according to  claim 30  using predetermined blade designed to cut varying depths, with duplicity of depths on each end part allowing for a primary cut ledge edge to each side of deeper cut to be manufactured, said matching ledges which will receive a panel of industry thickness which spans and covers deeper void housing items desired to be hidden within material and allows it to be fastened with surface of said panel and receiving material flush and so require no other furring.  
     
     
         32 . Process according to  claim 30  of a hand held machine capable of modifying three surfaces simultaneously so that openings can have two opposite faces and common joining face architecturally finished in one step.  
     
     
         33 . Process according to  claim 21  wherein a hand held tool is able to cut an elongated shaft of material out of a block using a single blade, by 
 a) blade being formed in a circular ring with at least one planar side having teeth, and  
 b) tool having driving and stabilizing mechanisms which allow blade to be rotated and as rotated cut out solid piece of material in which blade is imbedded and encompasses.  
 
     
     
         34 . Process according to  claim 1  wherein a machine crushes and pulverizes waste cementitious material into a preferred size and said machine receives neutralizers and other desired ingredients so end product is no longer a waste product but now used as a nutritional enhancing soil conditioner.  
     
     
         35 . Process according to  claim 1  wherein a device in one motion is able to remove excess material from face of a surface and smooth out any residual material so that no other finish work is required, device having, 
 a.) front leading blade at such an angle as to maximize ability to remove excess material and not gouge surface,  
 b.) handle at such an angle so that balances said blade and roller,  
 c.) roller being such that while it smoothes out residual material it also serves as wheels which movement facilitates process, and  
 d.) an end following device which cleans off any residual material which may accumulate on said roller.  
 
     
     
         36 . Process according to  claim 30  wherein precision guidance is realized by a device which acts as a template for cutting utensil by said guidance device being formed in predetermined shape equal to formula: desired cut plus cutting mechanism equals size, device being 
 a.) a single unit with design emulating desired cut in open or closed frame type,  
 b.) device itself having protrusions which penetrate into material being cut so that no other fastening mechanism is required,  
 c.) guidance device has structural ability to withstand being driven into material.  
 
     
     
         37 . Process according to  claim 1  wherein a cutting tool has a blade which is able to enter a material and cut it in desired direction without any surface preparation, cutting device employing the use of guidance plunge bars and coordinated with said guidance system of  claim 30 , blade having, 
 a) an elongate member of suitable saw blade material having a width, length, thickness, a first leading edge, a second trailing edge, a first end and a second end; said first end being provided with means to connect to a reciprocating mechanism; said first leading edge having saw teeth extending from second end to a first position adjacent the means to connect to a reciprocating mechanism,  
 b) wherein said teeth are of uniform size from first end until beginning of arc on leading edge near second point, where teeth are of closer proximity along arc of first leading edge, which arc terminates at middlest point of blade width, which point is convergence of leading edge and second end and trailing edge; and from second end trailing edge arcs away towards first end with teeth of closer proximity but teeth are positioned to be of neutral cutting angle having points perpendicular to direction of blade length until arc ceases into straight line of trailing edge which continues to first end; so that blade resembles a sword with teeth along leading edge and teeth only on first section of second point on following edge of point.  
 
     
     
         38 . Process according to  claim 1  wherein a device inserts and fastens wiring into a slot which has a narrow opening near floor level and then rises up into a material so that slot is hidden from view whereby tool has, 
 a.) long handle with shorter curved piece turned upward  
 b.) at end of said upward curve a mechanism for holding wire and simultaneously feeding it to desired location,  
 c.) fastening device for securing wire able to be directed from long end of said handle.  
 
     
     
         39 . Process according to  claim 1  wherein an air duct system is manufactured within a structural component of building and which component when placed in position connects to other such components so that result is a continuous interconnected duct system, and openings for serving rooms are made by penetrating said structural component and duct system, result being said system's air supply is sufficient to service the building.  
     
     
         40 . Process according to  claim 1  wherein said walls are completely constructed for a structure having a plurality of living levels and only after walls are constructed are the floor and roof systems installed by resting said floor system on a reinforced ledge which is a structural component of wall system having an architecturally finished face protruding from said wall and 
 a.) the gap between said floor system and said wall is converted into a bond beam by rebar and cementitious material being placed into said gap and  
 c.) said gap is also converted to a utility chase by area not used as bond beam having utilities placed therein and then finished floor hiding utilities from view.  
 
     
     
         41 . Process according to claim  40  wherein said walls are completely constructed for a structure having a plurality of living levels and only after walls are constructed are the floor and roof systems installed by resting said floor system on a reinforced ledge which is a steel plate inserted into wall system and creates said ledge by protruding from said wall and 
 a) said steel plate is welded at joints to form a continuous reinforcing and thereby becomes a structural bond beam as well as supporting ledge.