Prefabricated shell concrete structural components

Abstract

A concrete shell is formed as a mold for substantial concrete structures. The shell includes an interior mesh element that will be encapsulated in concrete in the poured concrete structure. A panel of moisture impervious material forms an outer layer of the concrete shell and acts as a form for field poured concrete making up a structural concrete element.

1 . A prefabricated concrete shell forming a component of a concrete structural element, the prefabricated shell comprising: 
 a. concrete;    b. an additive mixed into the concrete before the concrete is cured;    c. a panel of fluid impervious material forming a surface of the prefabricated shell;    d. a locator extending from the panel of fluid impervious material;    e. a sheet of mesh fabric spaced apart from the panel, the sheet located in position by a locator.    
   
   
       2 . The invention in accordance with  claim 1  wherein the additive comprises a reactive pozzolan.  
   
   
       3 . The invention in accordance with  claim 1  wherein the additive comprises silica-fume.  
   
   
       4 . The invention in accordance with  claim 1  wherein the additive comprises ground granulated blast furnace slag.  
   
   
       5 . The invention in accordance with  claim 1  wherein the sheet of mesh fabric is a carbon fiber mesh grid.  
   
   
       6 . The invention in accordance with  claim 1  wherein the panel of fluid impervious material comprises a substantially non-metallic membrane.  
   
   
       7 . The invention in accordance with  claim 5  wherein the sheet of mesh fabric is nonmetallic.  
   
   
       8 . The invention in accordance with  claim 5  wherein the sheet of mesh fabric is oxidation resistant.  
   
   
       9 . The invention in accordance with  claim 5  wherein the sheet of mesh fabric is carbon fiber.  
   
   
       10 . The invention in accordance with  claim 1  wherein the panel of fluid impervious material is fiberglass.  
   
   
       11 . The invention in accordance with  claim 1  wherein the panel of fluid impervious material further comprises a resin coating.  
   
   
       12 . The invention in accordance with  claim 1  wherein the locator is nonmetallic.  
   
   
       13 . The invention in accordance with  claim 1  wherein the locator is substantially nonmetallic.  
   
   
       14 . The invention in accordance with  claim 12  wherein the locator is attached to the sheet of mesh fabric and to a panel of fluid impervious material.  
   
   
       15 . A method of making a prefabricated shell comprising the acts of: 
 providing a mold, the mold being a surface wherein the prefabricated shell is molded;    providing a panel of fluid impervious material comprising an interior surface;    positioning locators proximate the panel of fluid impervious material of the form;    providing a sheet of mesh fabric and locating the sheet of mesh fabric proximate the panel of fluid impervious material of the form;    placing the panel of fluid impervious material, locators and sheet of mesh fabric in the mold;    pouring concrete into the mold, whereby the sheet of mesh fabric and the locators are surrounded by concrete and the concrete contacts the interior surface of the panel of fluid impervious material.    
   
   
       16 . The method of  claim 15  further comprising the act of curing the concrete in the mold to form a prefabricated shell.  
   
   
       17 . The method of  claim 15  wherein the concrete comprises reactive pozzolan as an additive to the concrete.  
   
   
       18 . The act as set forth in  claim 15  further comprising the acts of connecting a locator to the fluid impervious material and connecting a locator to the sheet of mesh fabric.  
   
   
       19 . A concrete structure comprising; 
 prefabricated concrete shell forming a component of a concrete structural element, the prefabricated shell comprising: 
 concrete including an additive mixed into the concrete before the concrete is cured;  
 a panel of fluid impervious material forming a surface of the prefabricated shell;  
 a locator extending from the panel of fluid impervious material;  
 a sheet of mesh fabric spaced apart from the panel, the sheet located in position by the locators;  
   a core of concrete located inside the prefabricated concrete shell, the core of concrete adjacent the panel of fluid impervious material, the core of concrete having an additive mixed into the procured concrete, the additive in the concrete being of a lesser amount by percentage than the additive used in the concrete of the prefabricated concrete shell.    
   
   
       20 . The invention in accordance with claim  21  wherein the additive is silica-fume.