Poured-in-place concrete construction components and method of construction

Abstract

A lightweight poured-in-place concrete builiding component and method of construction in which a plurality of spaced apart structural members with outer regions and a retaining layer system create a segmented form into which a lightweight concrete slurry is poured. The retaining layer system includes a lath which extends across the structural members on at least one outer region of the structual members. The lath is configured to simultaneously support a significant amount of the lightweight concrete slurry within a segmented form and allow a small amount to exude through the lath, thereby reinforcing a concrete component once cured. Alternative embodiments include the introduction of a barrier between a significant portion of a lath and concrete slurry to, at least reduce the amount on concrete which exudes-through the lath. Other altnerative embodiments include the introduction of insulative materials to the concrete slurry to enhance the insulative qualitites of a concrete component.

1 . A poured-in-place horizontal slab comprising: 
 a plurality of spaced-apart horizontal support members, each having a lower region; and    a retaining layer system further comprising a lath extending across and attached to said lower region to form a segmented form, said retaining layer system being configured to simultaneously retain a significant amount of a lightweight concrete slurry poured within said segmented form, and support said lightweight concrete during curing to form the horizontal slab, and said lath having a plurality of aperatures which allow a small amount of said concrete slurry to exude through said lath.    
     
     
         2 . The poured-in-place horizontal slab, as recited in  claim 1 , wherein said retaining layer system further comprises a barrier disposed between said lath and said fluid concrete to at least reduce the exuding of said concrete slurry thorugh said lath.  
     
     
         3 . The poured-in-place horizontal slab, as recited in  claim 1 , wherein an insulative material is positioned adjacent to said support members and in contact with at least one surface of said lightweight concrete.  
     
     
         4 . The poured-in-place horizontal slab, as recited in  claim 1 , wherein a covering is attached to an upper surface of said lightweight concrete.  
     
     
         5 . A poured-in-place wall comprising: 
 a plurality of spaced apart vertical support members with outer regions; and    a retaining layer system comprising a lath, wherein said support members are disposed within said retaining layer system and at least one of said outer regions is adjacent to said lath to form a segmented form, said retaining layer system being configured to retain a significant amount of a lightweight concrete slurry poured within said segmented form, and further configured to support said lightweight concrete during curing to form the horizontal slab, and said lath having a plurality of aperatures which allow a small amount of said lightweight concrete slurry to exude through said lath.    
     
     
         6 . The poured-in-place wall, as recited in  claim 5 , wherein said retaining layer system further comprises a form wall, said form wall extends across said plurality of support members on at least one said outer regions opposite said lath, said form wall configured to support a fluid, lightweight concrete within said segmented form during curing to form the wall  
     
     
         7 . The poured-in-place wall, as recited in  claim 6 , wherein a barrier is disposed between said lath and said concrete, said barrier configured to at least reduced said concrete from exuding away from said segmented form.  
     
     
         8 . The poured-in-place wall as recited in  claim 7 , wherein said barrier has insulative qualities.  
     
     
         9 . The poured-in-place wall as recited in  claim 5 , wherein an insulative material is positioned within said segmented form to provide the wall with insulative qualities.  
     
     
         10 . The poured-in-place wall, as recited in  claim 5 , wherein a covering is attached to said retaining layer system.  
     
     
         11 . A method of constructing a poured-in-place construction components utilizing a lightweight concrete comprising the steps of: 
 establishing at plurality of structural members spaced at a pre-determined distance;    creating a segmented form by fixing a retaining layer system, comprising a lath, around said structural members, wherein said lath extends across said plurality of structural members on at least one outer region to support a significant amount of a lightweight concrete slurry poured within said segmented form;    pouring said lightweight concrete slurry into said segmented form to at least cover a substantial portion of said structural members and exude a small portion through said lath; and    curing said lightweight concrete slurry to a rigid state so that said lightweight concrete is fixed in said segmented form thereby creating the construction component.    
     
     
         12 . The method of constructing a poured-in-place construction component as recited in  claim 11 , wherein the step of creating a segmented form further comprises the step of placing a form-wall across said plurality of structural members opposite of said lath to support a fluid, lightweight concrete within said segmented form during curing to form the wall.  
     
     
         13 . The method of constructing a poured-in-place construction component as recited in  claim 11 , further comprising the step of placing a barrier between said lath and said concrete, said barrier configured to at least reduced said concrete from partially exuding thorugh said lath.  
     
     
         14 . The method of constructing a poured-in-place construction component as recited in  claim 13 , further comprising the step of inserting an insulative material within said segmented form to provide the construction component with insulative qualities.  
     
     
         15 . The method of constructing a poured-in-place construction component as recited in  claim 11 , further comprising the step of attaching a covering to said retaining layer system.  
     
     
         16 . The method of constructing a poured-in-place, construction component as recited in  claim 12 , further comprising the step of removing said form wall when said concrete has cured.  
     
     
         17 . The method of construcing a poured-in-place construction component as recited in  claim 16 , further comprising the step of attaching a covering to said cured concrete.