Concrete floor and ceiling system without steel reinforcing

Abstract

A building component system including a rigid plastic form having an arched shape in each of two perpendicular vertical planes and having a plurality of protrusions configured to engage concrete poured on top of the rigid plastic form. The system also includes concrete poured on top of the form and cured to bind to the form at least at the plurality of protrusions, thereby forming an arched ceiling for a first story of a building and a flat roof or flat floor for a second story of a building.

What is claimed is: 
     
         1 . A building component system comprising:
 a rigid plastic form having an arched shape in each of two perpendicular vertical planes and having a plurality of protrusions configured to engage concrete poured on top of the rigid plastic form; and   concrete poured on top of the form and cured to bind to the form at least at the plurality of protrusions, thereby forming an arched ceiling for a first story of a building and a flat roof or flat floor for a second story of a building, wherein the form is not removed and stays in place after the concrete cures.   
     
     
         2 . The system of  claim 1  wherein, when the form is placed on a flat surface, a space below the form is sufficient for use as a residence for humans or animals or equipment or some combination. 
     
     
         3 . The system of  claim 1  wherein the concrete is not reinforced with steel. 
     
     
         4 . The system of  claim 1  further comprising two or more temporary vertical forms disposed outside the rigid plastic form for providing an outer perimeter of the building component, wherein the temporary vertical forms are removed after the concrete is poured and cured. 
     
     
         5 . The system of  claim 1  wherein a plurality of the rigid plastic forms stack efficiently for transportation of the plurality of rigid plastic forms. 
     
     
         6 . The system of  claim 1  further comprising a mold configured to fabricate the rigid plastic form by injection molding. 
     
     
         7 . The system of  claim 1  wherein the arches are parabola shaped and designed to push the concrete to pure compression. 
     
     
         8 . The system of  claim 1  wherein the arches provide a great vertical extent so that the concrete is working more in compression and less reliant on the tensile strength of the form. 
     
     
         9 . A method comprising:
 placing a rigid plastic form having an arched shape in each of two perpendicular vertical planes and having a plurality of protrusions configured to engage concrete poured on top of the rigid plastic form;   placing two or more simple vertical forms outside the rigid plastic form for providing an outer perimeter of a building component;   pouring and curing concrete on top of the form to bind to the form at least at the plurality of protrusions; and   after the concrete cures removing the two or more simple vertical forms, thereby forming an arched ceiling for a first story of a building and a flat roof or flat floor for a second story of a building.