Pre-shaped form construction components, system, and method of construction using the same

Abstract

A building component includes a form that is pre-shaped. The form includes a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment is between the channel segment and the corresponding channel segment, and when respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel is created between the form and the corresponding form. Further, when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel is created between the form and the corresponding form.

1 . A building component, comprising:
 a form that is pre-shaped and made of a lightweight cementious material, the form having a channel segment that extends along at least a part of the form, a profile of the channel segment being defined, at least in part, by a first portion that projects in a first direction and a second portion that projects in a second direction that is transverse to the first direction, and the profile of the channel segment being defined from a perspective of looking at the channel segment in line with a direction of extension of the at least one channel segment,   wherein the form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment, the abutment being between the channel segment and the corresponding channel segment such that at least one of a beam channel or a column channel is created between the form and the corresponding form.   
     
     
         2 . The building component according to  claim 1 , wherein the channel segment surrounds at least a portion of an outer perimeter of the form. 
     
     
         3 . The building component according to  claim 1 , wherein a thickness of the form at the channel segment is less than a thickness of the form away from the channel segment, the thickness being defined as a distance between a front surface and a back surface opposite the front surface. 
     
     
         4 . The building component according to  claim 1 , wherein a thickness of the form is substantially uniform across an entirety of the form, the thickness being defined as a distance between a front surface and a back surface opposite the front surface. 
     
     
         5 . The building component according to  claim 4 , wherein the channel segment is disposed into peripheral edges of the form between the front surface and the back surface. 
     
     
         6 . The building component according to  claim 1 , wherein the cross-section of the channel segment is further defined by a third portion that projects in the first direction in parallel with the first portion. 
     
     
         7 . The building component according to  claim 1 , wherein the channel segment is a first channel segment, and
 wherein the form further includes a second channel segment that extends in a direction orthogonal to a direction of extension of the first channel segment.   
     
     
         8 . The building component according to  claim 1 , further comprising a structural reinforcement member engaged with the form. 
     
     
         9 . The building component according to  claim 8 , wherein the structural reinforcement member includes one or more of: rebar, wire mesh, carbon fiber, or one or more dowels. 
     
     
         10 . The building component according to  claim 8 , wherein the structural reinforcement member is embedded, at least in part, within the form. 
     
     
         11 . A building component, comprising:
 a form that is pre-shaped, the form including a channel segment, defined, at least in part, by a base region and a wall that extends from the base region,   wherein the form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment, the abutment being between the channel segment and the corresponding channel segment, and   wherein:
 when respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel is created between the form and the corresponding form, and 
 when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel is created between the form and the corresponding form, and 
   wherein the form is made of a lightweight cementious material having a composition that provides a chemical and/or physical property such that, upon pouring and setting of a reinforced concrete mix into the beam channel or the column channel, the form bonds irreversibly to the reinforced concrete mix.   
     
     
         12 . The building component according to  claim 11 , wherein the wall of the channel segment is a first wall, the first wall extending from a first side of the base region, and
 wherein the channel segment is further defined by a second wall that extends from a second side of the base region, the second side being opposite the first side.   
     
     
         13 . The building component according to  claim 11 , wherein the form is a substantially planar panel, and the channel segment extends along at least a portion of a perimeter of the form. 
     
     
         14 . The building component according to  claim 11 , wherein the form has a first side that is convex and a second side that is concave, and the channel segment extends along the concave second side. 
     
     
         15 . (canceled) 
     
     
         16 . The building component according to  claim 11 , wherein the form includes a chase to accommodate wiring in the building structure. 
     
     
         17 . A method of constructing a building structure, the method comprising:
 disposing a form in a position for constructing a portion of the building structure, the form being pre-shaped and made of a lightweight cementious material, and the form including a channel segment, defined, at least in part, by a base region and a wall that extends from the base region;   abutting a corresponding form having a corresponding channel segment against the form such that:
 the channel segment and the corresponding channel segment are aligned, and 
 at least one of a beam channel or a column channel is created between the form and the corresponding form; and 
   pouring a reinforced concrete mix into the at least one of the beam channel or the column channel such that the form and the corresponding form are a permanent fixture with the reinforced concrete.   
     
     
         18 . The method according to  claim 17 , further comprising aligning a structural reinforcement member with at least one of the form or the corresponding form. 
     
     
         19 . The method according to  claim 17 , further comprising aligning a structural reinforcement member within the at least one of the beam channel or the column channel. 
     
     
         20 . The method according to  claim 17 , further comprising arranging the form and the corresponding form to create one of a wall, a support column, or a support beam of the building structure.