Safe room ii

Abstract

A method for manufacturing a precast shelter is provided. The method can include constructing an inner mold core, adding a base frame around a perimeter of the inner mold core, horizontally placing a plurality of steel rods on top of the inner mold core, connecting different ends of the horizontally placed steel rods to reinforcing bar segments of the base frame with vertically positioned steel rods, and placing an outer mold shell opposite the inner mold core so as to define a cavity. The method can further include pouring concrete into the cavity and on top of the cap over the horizontally placed steel rods, waiting for the poured concrete to partially cure, and removing the outer mold shell and the inner mold core subsequent to partially curing the poured concrete to produce a unibody precast shelter.

1 . A method of manufacturing a precast shelter, the method comprising:
 constructing an inner mold core to include exterior walls enclosing an interior space and a cap covering a top opening of the interior space;   adding a base frame around a perimeter of the inner mold core using a set of base rails and reinforcing bar segments affixed to different portions of the base rails;   horizontally placing a plurality of steel rods on top of the cap;   connecting different ends of the horizontally placed steel rods to the reinforcing bar segments with vertically positioned steel rods;   placing an outer mold shell opposite an exterior surface of the inner mold core so as to define a cavity between an interior surface of the outer mold shell and the exterior surface of the inner mold core, the cavity containing the base frame and the vertically positioned steel rods;   pouring concrete into the cavity and on top of the cap over the horizontally placed steel rods;   waiting for the poured concrete to partially cure; and,   removing the outer mold shell and the inner mold core subsequent to partially curing the poured concrete to produce a unibody precast shelter.   
     
     
         2 . The method of  claim 1 , further comprising attaching a plurality of lifting eyes to at least one of the horizontal placed steel rods. 
     
     
         3 . The method of  claim 1 , further comprising securing a plurality of welded wire mesh sheets to at least one of the horizontal placed steel rods. 
     
     
         4 . The method of  claim 1 , further comprising securing a plurality of welded wire mesh sheets to at least one of the vertically positioned steel rods along at least one exterior wall of the inner mold core. 
     
     
         5 . The method of  claim 1 , wherein removing the outer mold shell and the inner mold core subsequent to partially curing the poured concrete to produce a unibody precast shelter, comprises:
 inserting a plurality of jacks in a support base, wherein each jack is aligned with an aperture in the support base, the aperture being located at the approximate corner of the support base;   extending the jack until the shelter is released from the inner mold core.   
     
     
         6 . The method of  claim 1 , wherein the inner mold core is rectangular shaped. 
     
     
         7 . The method of  claim 1 , wherein a base rail includes a substantially C-shaped channel having a pair of top edges and a channel bottom section defined between the pair of top edges. 
     
     
         8 . The method of  claim 1 , wherein an outer side surface of the base frame is flush with the exterior surface of the inner mold core. 
     
     
         9 . The method of  claim 7 , wherein the end of each plurality of reinforcing bar segments is welded on center on a top surface of the channel bottom section of at least one base rail of the plurality of base rails. 
     
     
         10 . The method of  claim 1 , wherein waiting for the poured concrete to partially cure further comprises waiting for a sample of the poured concrete to reach a desired strength of at least three thousand pounds per square inch when measured at a twenty-four hour concrete test, the sample taken during the pouring of the concrete into the cavity. 
     
     
         11 . The method of  claim 1 , wherein the unibody precast shelter withstands wind speeds of at least two hundred fifty miles per hour. 
     
     
         12 . The method of  claim 1 , wherein the unibody precast shelter withstands a wood board missile traveling horizontally at up to and including one hundred miles per hour and vertically at up to and including sixty seven miles per hour. 
     
     
         13 . The method of  claim 12 , where the wood board missile is a fifteen pound two by four. 
     
     
         14 . The method of  claim 1 , further comprising forming a community safe room by coupling a plurality of unibody precast shelter.