Building with foam cored ribs and method

Abstract

A building includes an inflatable form having an interior surface bounding a chamber. A stabilizing layer of polymeric foam or cementitious material is disposed on the interior surface of the inflatable form. At least one support layer of cementitious material is disposed on the interior surface of the stabilizing layer. Finally, one or more ribs project from the interior surface of the at least one support layer. Each rib includes a core of polymeric foam and a layer of cementitious material disposed over the core.

1 . A method of forming a building comprising: 
 inflating an inflatable form such that a chamber bounded by an interior surface of the inflatable form has a first air pressure that supports the inflatable form;    applying a stabilizing layer comprised of a polymeric foam on the interior surface of the inflatable form, the stabilizing layer having reinforcing line at least partially embedded therein;    positioning at least one support layer comprised of a cementitious material on an interior surface of stabilizing layer; and    increasing the air pressure within the chamber at some time after applying the stabilizing layer, the reinforcing line being at least partially embedded within the stabilizing layer so that tension on the reinforcing line is increased as the air pressure is increased within the chamber, whereby at least a portion of the load applied by the increased air pressure is absorbed by the reinforcing line.    
   
   
       2 . The method as recited in  claim 1 , wherein the inflatable form is inflated without mechanically constraining an exterior surface of the inflatable form.  
   
   
       3 . The method as recited in  claim 1 , further comprising applying retention line over an exterior surface of the inflatable form so as to restrain expansion of the inflatable form.  
   
   
       4 . The method as recited in  claim 1 , wherein the polymeric foam is sprayed onto the interior surface of the inflatable form.  
   
   
       5 . The method as recited in  claim 1 , wherein the step of applying the stabilizing layer comprises: 
 spraying a first layer of polymeric foam onto the interior surface of the inflatable form;    securing the reinforcing line along an interior surface of the first layer of polymeric foam; and    spraying a second layer of polymeric foam onto the interior surface of the first layer of polymeric so as to at least partially embed the reinforcing line within the polymeric foam.    
   
   
       6 . The method as recited in  claim 5 , further comprising tensioning the reinforcing line along the length thereof after or while securing the reinforcing line to the first layer of polymeric foam but prior to spraying the second layer of polymeric foam.  
   
   
       7 . The method as recited in  claim 1 , further comprising mechanically connecting the reinforcing line to the stabilizing layer at at least two spaced apart locations along the reinforcing line.  
   
   
       8 . The method as recited in  claim 1 , wherein the support layer is sprayed onto the interior surface of the stabilizing layer.  
   
   
       9 . The method as recited in  claim 1 , further comprising a forming a rib on the interior surface of the at least one support layer.  
   
   
       10 . The method as recited in  claim 1 , further comprising: 
 forming a core comprised of polymeric foam directly on or inwardly spaced from the interior surface of the at least one support layer; and    applying a layer of cementitious material over the core so as to form a rib.    
   
   
       11 . The method as recited in  claim 1 , further comprising: 
 forming a first core and a spaced apart second core on the interior surface of the at least one support layer, the first core and second core being comprised of a polymeric foam;    producing a strut comprised of cementitious material between the first core and the second core; and    applying a layer of cementitious material over the first core, second core, and strut.    
   
   
       12 . A method of forming a building comprising: 
 inflating an inflatable form having an interior surface;    applying a stabilizing layer comprised of a polymeric foam on the interior surface of the inflatable form;    positioning at least one support layer comprised of a cementitious material on an interior surface of stabilizing layer; and    forming a rib on the interior surface of the at least one support layer, the rib comprising: 
 a core comprised of a polymeric foam; and  
 a layer of cementitious material disposed over the core.  
   
   
   
       13 . The method as recited in  claim 12 , wherein the inflatable form is inflated without mechanically constraining an exterior surface of the inflatable form.  
   
   
       14 . The method as recited in  claim 12 , further comprising applying retention line over an exterior surface of the inflatable form so as to restrain expansion of the inflatable form.  
   
   
       15 . The method as recited in  claim 12 , wherein the step of applying the stabilizing layer comprises: 
 spraying a first layer of polymeric foam onto the interior surface of the inflatable form;    securing a reinforcing line along an interior surface of the first layer of polymeric foam; and    spraying a second layer of polymeric foam onto the interior surface of the first layer of polymeric so as to at least partially embed the reinforcing line within the polymeric foam.    
   
   
       16 . The method as recited in  claim 15 , further comprising tensioning the reinforcing line along the length thereof after or while securing the reinforcing line to the first layer of polymeric foam but prior to spraying the second layer of polymeric foam.  
   
   
       17 . The method as recited in  claim 15 , further comprising mechanically connecting the reinforcing line to the stabilizing layer at at least two spaced apart locations along the reinforcing line.  
   
   
       18 . The method as recited in  claim 12 , wherein the support layer is sprayed onto the interior surface of the stabilizing layer.  
   
   
       19 . The method as recited in  claim 12 , further comprising: 
 forming a core comprised of polymeric foam directly on or inwardly spaced from the interior surface of the at least one support layer; and rib.    applying a layer of cementitious material over the core so as to form a    
   
   
       20 . The method as recited in  claim 12 , further comprising: 
 forming a first core and a spaced apart second core on the interior surface of the at least one support layer, the first core and second core being comprised of a polymeric foam;    producing a strut comprised of cementitious material between the first core and the second core; and    applying the layer of cementitious material over the first core, second core, and strut.