System and method for the rapid manufacturing of concrete modular housing units

Abstract

A system for accelerated manufacturing of concrete modular housing units including a first deck platform including a plurality of exterior movable wall forms. A second deck platform includes a plurality of exterior movable wall forms. A first concrete slab is placed on the first deck platform. At least one core including a plurality of core walls placed on the first concrete slab. The exterior movable wall forms of the first deck platform are positioned proximate the core walls to define a wall space there between configured to receive wet concrete and create a first concrete modular housing unit. A second concrete slab is placed on the second deck platform. Wet concrete in the wall space partially cures before the at least one core is removed from the first concrete slab and placed on the second concrete slab, allowing cores to be reused one or more times.

What is claimed is: 
     
         1 . A system for manufacturing concrete modular housing units, the system comprising:
 a first deck platform including a first plurality of exterior movable wall forms;   a first concrete slab placed on the first deck platform;   at least one core positioned on the first concrete slab and including a plurality of core walls, wherein each of the first plurality of exterior movable wall forms of the first deck platform are positioned proximal to the plurality of core walls to define a wall space therebetween, the wall space being configured to receive a wet concrete therein;   a second deck platform including a second plurality of exterior movable wall forms; and   a second concrete slab placed on the second deck platform, the second concrete slab being configured to receive a partially cured concrete from the first concrete slab,   wherein one of the first concrete slab and the second concrete slab further includes a plurality of female inserts each configured to receive a rod therein.   
     
     
         2 . The system of  claim 1 , wherein the at least one core is configured to engage the second deck platform in an inverted position. 
     
     
         3 . The system of  claim 1 , wherein the at least one core further includes at least one movable corner slug. 
     
     
         4 . The system of  claim 3 , wherein the at least one movable corner slug is substantially V-shaped. 
     
     
         5 . The system of  claim 1 , wherein at least one of the plurality of core walls further includes an alignment pin on one of a bottom surface and a top surface thereof. 
     
     
         6 . The system of  claim 1 , wherein the at least one core includes a plurality of cores. 
     
     
         7 . The system of  claim 1 , further comprising a plurality of bent rods protruding substantially upwardly from one of the first concrete slab and the second concrete slab. 
     
     
         8 . The system of  claim 7 , further including a reinforcing cage positioned about the at least one core and attached to one of the plurality of bent rods. 
     
     
         9 . The system of  claim 1 , further including a reinforcing cage positioned about the at least one core and coupled to one of the plurality of female inserts through the rod therein. 
     
     
         10 . A system for manufacturing concrete modular housing units, the system comprising:
 a first deck platform including a first plurality of exterior movable wall forms;   a first concrete slab placed on the first deck platform;   at least one core positioned on the first concrete slab and including a plurality of core walls, wherein each of the first plurality of exterior movable wall forms of the first deck platform are positioned proximal to the plurality of core walls to define a wall space therebetween, the wall space being configured to receive a wet concrete therein;   a second deck platform including a second plurality of exterior movable wall forms;   a second concrete slab placed on the second deck platform, the second concrete slab being configured to receive a partially cured concrete from the first concrete slab; and   at least one gasket positioned on a selected one of the first deck platform and the second deck platform, the at least one gasket being configured to engage one of the first concrete slab and the second concrete slab with the selected one of the first deck platform and the second deck platform.   
     
     
         11 . The system of  claim 10 , wherein the at least one core further includes at least one movable corner slug. 
     
     
         12 . The system of  claim 11 , wherein the at least one movable corner slug is substantially V-shaped. 
     
     
         13 . The system of  claim 10 , wherein at least one of the plurality of core walls further includes an alignment pin on one of a bottom surface and a top surface thereof. 
     
     
         14 . The system of  claim 10 , wherein at least one of the first concrete slab and the second concrete slab further includes a plurality of precast slots therein. 
     
     
         15 . The system of  claim 10 , further comprising an embed coupled to one of the first concrete slab and the second concrete slab, wherein the embed is configured to stabilize and level one of the first concrete slab and the second concrete slab at a predetermined elevation. 
     
     
         16 . A system for manufacturing concrete modular housing units, the system comprising:
 a first deck platform including a first plurality of exterior movable wall forms;   a first concrete slab placed on the first deck platform;   a plurality of cores positioned on the first concrete slab, the plurality of cores including a respective plurality of core walls, wherein each of the first plurality of exterior movable wall forms of the first deck platform are positioned proximal to the plurality of core walls to define a wall space therebetween, the wall space being configured to receive a wet concrete therein;   a second deck platform including a second plurality of exterior movable wall forms; and   a second concrete slab placed on the second deck platform, the second concrete slab being configured to receive a partially cured concrete from the first concrete slab.   
     
     
         17 . The system of  claim 16 , wherein at least one of the first concrete slab and the second concrete slab further includes a plurality of precast slots therein. 
     
     
         18 . The system of  claim 16 , wherein at least one of the plurality of core walls further includes an alignment pin on one of a bottom surface and a top surface thereof 
     
     
         19 . The system of  claim 18 , wherein at least one of the first concrete slab and the second concrete slab further includes a plurality of precast slots therein, and wherein the alignment pin mates with one of the plurality of precast slots such that each of the plurality of cores is positioned at a predetermined location on one of the first concrete slab and the second concrete slab. 
     
     
         20 . The system of  claim 16 , further comprising a plurality of bent rods protruding substantially upwardly from one of the first concrete slab and the second concrete slab.