Modular building construction employing concrete mold assembly

Abstract

A modular building construction where each module consists of self-contained molds to allow concrete to form within the walls of each module as well as between the modules when two or more modules are placed together. The structural load capacities of the modules are transmitted directly into the concrete within the wall without bearing directly on the module below. The forming structure for the modules can be fabricated either using wood or metal construction. The exterior and interior wall finishes are the resulting structure of the molds. Since the molds are self-contained the walls can consist of, either drywall, rigid insulation, thin brick or siding just to name a few. The interior forming structure can extend into the concrete footing or above or to adjacent modules to structurally secure the modules together. The modules can be built with a flooring structure as well as ceiling. The interior walls as well as the floor and ceiling also function as wall supporting braces. The exterior walls have many different forming molds to accommodate many different construction situations. Some forming structures are formed with a thermal break between the exterior and interior forming structure. The thermal break allows the wall to also be used as a heating or cooling distribution system. Different types of connectors are described allowing for the connectors to be hidden. Several methods are shown how the electrical distribution can be provided within a concrete wall by using the forming structure within the mold. A ribbed concrete mold can be formed for a poured-in-place wall as well as for a floor and roof system. Temporary floor bracing can be used when pouring the flooring system, or only just the concrete beams can be poured and the floor can be poured later. The flooring system can be used as concrete wall or as a roof structure.

1 . A building construction consisting of plural individual modules, each module is characterized by cavity walls comprising a self-contained mold for receiving concrete therein.  
   
   
       2 . The construction according to  claim 1  in which said walls are constructed of wood studs.  
   
   
       3 . The construction according to  claim 1  in which said walls are constructed of metal studs.  
   
   
       4 . The construction according to  claim 1  in which selected ones of said walls include an interior and an exterior finish.  
   
   
       5 . The construction according to  claim 1  in which selected ones of said walls extend downward whereby to enable formation of a continuous concrete footing when concrete is introduced into said one of said walls.  
   
   
       6 . The construction according to  claim 1  in which said structure includes a roof portion capable of receiving concrete introduced therein.  
   
   
       7 . The construction according to  claim 1  in which steel reinforcing means are introduced into said walls prior to introduction of concrete into said wall.  
   
   
       8 . The construction according to  claim 1  in which composite board forms the exterior finish of said walls.  
   
   
       9 . The construction according to  claim 1  in which a pair of modules are disposed separated by an air space, ceiling and floor joists span the full length of one of said modules and are connected by with solid bridging between each joist.  
   
   
       10 . The construction according to  claim 1  in which the exterior of the module wall is left with drywall, studs, ceiling joists, blocking, and floor joists.  
   
   
       11 . The construction according to  claim 1  in which the interior walls add additional bracing support to the exterior wall of the module.  
   
   
       12 . The construction according to  claim 9  in which floor and ceiling joists overlap the studs allowing concrete to flow under the joists whereby to form a solid concrete base so as to permanently rest upon the modules.  
   
   
       13 . The construction according to  claim 1  in which rigid insulation at the interior of the wall provides a thermal break between two separate chambers for installing concrete on either side of the thermal break.  
   
   
       14 . The construction according to  claim 13  in which the separate chambers are filled with two different materials on either side of the wall, one side having sand within one chamber and having gravel within the other chamber whereby the wall is provided with mass and gravel likewise provides mass, stabilizes said wall and rigidifies said wall.  
   
   
       15 . The construction according to  claim 14  which included a radiant heating system is provided with said wall capable of heating said gravel stones.  
   
   
       16 . The construction according to  claim 14  in which a cooling coil is provided within said wall capable of cooling said gravel stones.  
   
   
       17 . The construction according to  claim 14  in which said radiant heating system includes a source of hot water.  
   
   
       18 . The construction according to  claim 14  in which said gravel functions as a storage system for a solar heating system.  
   
   
       19 . The construction according to  claim 1  in which wire mesh is installed on one side of said mold and a textured concrete finish is applied to said wire mesh.  
   
   
       20 . The construction according to  claim 1  in which said walls are formed of hat channels.  
   
   
       21 . The construction according to  claim 1  in which said hat channels comprise a forming structure.  
   
   
       22 . The construction according to  claim 1  in which wire mesh is installed on one side of said mold and concrete is inserted into the mold, through the wire mesh and then formed to a desired finish.  
   
   
       23 . The construction according to  claim 1  in which said wall structure has smaller vertical C channels and horizontal hat channels.  
   
   
       24 . The construction according to  claim 23  in which the small vertical C channel is located at the flange of the vertical C channel creating a hollow chamber for electrical wiring.  
   
   
       25 . The construction according to  claim 1  in which a vertical open passage is connected to a horizontal open passage within the concrete wall created by the forming structure members within the all and conned by a hole between two open passages so as to accommodate utility distribution within the wall.  
   
   
       26 . The construction according to  claim 21  in which said electrical wiring is connected to the horizontal hat channel.  
   
   
       27 . The construction according to  claim 21  in which said electrical wiring is passed through the horizontal and vertical hat channels.  
   
   
       28 . The construction according to  claim 21  in which said forming structure criss-cross each other forming a rigid frame.  
   
   
       29 . The construction according to  claim 1  in which the floor and wall are connected to form a wall brace support to the walls of the module.  
   
   
       30 . The construction according to  claim 1  in which the ceiling and wall are connected to form a wall brace support to the walls of the module.  
   
   
       31 . The construction according to  claim 1  where the structural load capacity of the module floor and ceiling joists are transmitted directly onto the concrete within the wall without bearing directly on the module below.  
   
   
       32 . The construction according to  claim 20  in which the open cavity of the hat channel when placed against the composite board provides access for utility distribution within a concrete wall.  
   
   
       33 . The construction according to  claim 20  in which the flanges of the hat channels hold the composite board to the forming structure without using fasteners.  
   
   
       34 . The construction according to  claim 20  in which the C portion of the hat channels is an access for utility distribution.  
   
   
       35 . The construction according to  claim 20  in which the forming structures have holes.  
   
   
       36 . The construction according to  claim 1  in which the forming structure of said walls extend above, below or adjacent to a wall mold whereby to connect the forming structure to the wall to an adjacent module and are embedded with the concrete wall.  
   
   
       37 . The construction according to  claim 13  in which the wall is double sided, where the forming structure is a mirror image on both sides of the rigid insulation in the middle of the wall.  
   
   
       38 . The construction according to  claim 1  in which the horizontal bracing channel braces the rigid insulation in securing the wall.  
   
   
       39 . The construction according to  claim 3  in which the flanges of the H channels support the outer surface of the wall.  
   
   
       40 . The construction according to  claim 1  in which the foam spacers are added to the interior of the wall resulting in a ribbed concrete structure.  
   
   
       41 . The construction according to  claim 40  in which said interior foam spacer when installed less than full height will have concrete beams criss-crossing the ribbed concrete structure.  
   
   
       42 . The construction according to  claim 1  in which a connector secures the finished rigid boards.  
   
   
       43 . The construction according to  claim 42  in which an H connector wraps the edges of the composite board of the surface of the wall mold and the connector is secured to said forming structure of the mold.  
   
   
       44 . The construction according to  claim 42  in which one end of a connector is partially embedded in the composite board of the wall mold and the other end of the connector has a lip that penetrates through the hole in the forming structure of the mold.  
   
   
       45 . The construction according to  claim 14  in which the wall mold plus the filled material within the wall forms a concrete beam.  
   
   
       46 . The construction according to  claim 1  in which control joints are secured to the forming structure of the mold.  
   
   
       47 . The construction according to  claim 1  in which an expansion joint is secured to the forming structure of the mold.  
   
   
       48 . The construction according to  claim 47  in which two C channels span the full width of the forming structure are separated by caulk.  
   
   
       49 . The construction according to  claim 4  in which the exterior finish includes siding.  
   
   
       50 . The construction according to  claim 49  in which a vapor barrier is behind the siding.  
   
   
       51 . The construction according to  claim 4  were brick is installed as part of the exterior finish.  
   
   
       52 . The construction according to  claim 1  in which the corners of the interior forming structure has metal angle corners.  
   
   
       53 . The construction according to  claim 1  in which a U channel support the floor and ceiling joists when attached to the interior forming structure.  
   
   
       54 . The construction according to  claim 1  in which a C channel provides load bearing support when attached to the interior forming structure.  
   
   
       55 . The construction according to  claim 53  in which the U channel is a decorative accent strip.  
   
   
       56 . The construction according to  claim 54  in which the C channel is a decorative accent strip.  
   
   
       57 . The construction according to  claim 1  in which a removable wall form is attached to the forming structure of the mold and removed upon the curing of the concrete.  
   
   
       58 . The construction according to  claim 57  in which wall ties connect to the interior structure of the wall mold through the removable form.  
   
   
       59 . The construction according to  claim 1  in which a ribbed shaped interior forming mold comprising a composite board, an array of metal framing members and interior foam spacers capable of receiving concrete therein.  
   
   
       60 . The construction according to  claim 59  in which metal framing is used to support the composite board and the interior foam spacers.  
   
   
       61 . The construction according to  claim 59  in which steel reinforcing is installed in the mold.  
   
   
       62 . The construction according to  claim 59  in which the interior foam spacers are tapered.  
   
   
       63 . The construction according to  claim 59  in which the concrete within the mold is be poured to only the height of the beams and cured.  
   
   
       64 . The construction according to  claim 63  in which additional steel reinforcing is added to the beam prior to curing.  
   
   
       65 . The construction according to  claim 63  in which additional concrete is installed over the beams after the concrete beams have cured.  
   
   
       66 . The construction according to  claim 63  in which additional utilities are installed above the interior foam spacers.  
   
   
       67 . The construction according to  claim 59  in which the interior foam spacers are less than full length of the beams allowing installation of crossing beams to be installed.  
   
   
       68 . The construction according to  claim 59  in which temporary scaffolding can be installed.  
   
   
       69 . The construction according to  claim 59  in which includes a roof portion.  
   
   
       70 . The construction according to  claim 59  in which includes a floor portion.  
   
   
       71 . The construction according to  claim 69  in which the soffit, fascia and gutter is installed as an integral part of the roof portion.  
   
   
       72 . The construction according to  claim 69  in which the horizontal beam connects the wall to the roof portion.  
   
   
       73 . The construction according to  claim 69  in which additional hat channels are embedded in the roof portion prior to the curing of said concrete creating an air space under the roof shingles.