Nailable concrete formworks

Abstract

Disclosed is a concrete slab precursor comprising: an at least partially enclosed structure formed by one or more nailable formworks comprising a first concrete composition; wherein the at least partially enclosed structure comprises a defined area configured to receive a second concrete composition; wherein the first concrete composition is a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35% based on a total mass of dry material; and wherein the second concrete composition is the same as or different from the first concrete composition. Also disclosed is a concrete slab made from the disclosed concrete slab precursor and constructions formed from the same.

What is claimed is: 
     
         1 . A concrete slab precursor comprising:
 at least partially enclosed structure formed by one or more nailable formworks comprising a first concrete composition;   wherein the at least partially enclosed structure comprises a defined area configured to receive a second concrete composition;   wherein the first concrete composition is a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material; and   wherein the second concrete composition is the same as or different from the first concrete composition.   
     
     
         2 . The concrete slab precursor of  claim 1 , wherein the one or more nailable formworks further comprises a first concrete reinforcing element and/or a second concrete reinforcing element. 
     
     
         3 . The concrete slab precursor of  claim 2 , wherein the first concrete reinforcing element is embedded in the one or more nailable formworks such that at least a portion of the first concrete reinforcing element extends outside of a body of the one or more nailable formworks. 
     
     
         4 . The concrete slab precursor of  claim 2 , wherein the second concrete reinforcing element if present is disposed along at least a portion of the defined area or such that it covers an entire area of the defined area. 
     
     
         5 . The concrete slab precursor of  claim 2 , wherein the first concrete reinforcing element and/or the second concrete reinforcing element is rebar or reinforcement wire. 
     
     
         6 . The concrete slab precursor of  claim 2 , wherein the first concrete reinforcing element is configured to support the second concrete reinforcing element. 
     
     
         7 . The concrete slab precursor of  claim 1 , wherein the at least partially enclosed structure is formed by two or more nailable formworks. 
     
     
         8 . The concrete slab precursor of  claim 1 , wherein at least one boundary of the at least partially enclosed structure is a preexisting construction element, and wherein the one or more nailable formworks abut the preexisting construction element. 
     
     
         9 . The concrete slab precursor of  claim 1 , wherein the defined area further comprises an internal nailable formwork partitioning the defined area. 
     
     
         10 . The concrete slab precursor of  claim 1 , wherein the rubber is virgin and/or recycled and has a particle size no greater than about 0.5 inches. 
     
     
         11 . The concrete slab precursor of  claim 1 , wherein the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof. 
     
     
         12 . The concrete slab precursor of  claim 1 , wherein the nailable concrete composition further comprises water in an amount of about 20 wt % to about 40 wt % based on the water-to-cement ratio. 
     
     
         13 . The concrete slab precursor of  claim 1 , wherein the nailable concrete composition further comprises one or more fillers, plasticizers, water-reducing agents, pumping agents, air entrainers, set retarders, fire retardants, water repellants, defoamers, antifreeze agents, expanding agents, curing agents, coloring additives, anti-dispersant agents, mold release agents, antimicrobial agents, fire-retardants, antifungal agents, insect- and animal-repellant agents, anti-corrosion additive, adhesive additives, or any combination thereof. 
     
     
         14 . A concrete slab formed by:
 providing the concrete slab precursor of  claim 1 ; and   filling the defined area with the second concrete composition;   wherein the one or more nailable formworks are incorporated into the concrete slab and are not removed.   
     
     
         15 . The concrete slab of  claim 14 , wherein the at least partially enclosed structure is formed by four or more nailable formworks, or by at least one nailable formwork and a preexisting construction element. 
     
     
         16 . The concrete slab of  claim 14 , further comprising a first construction element nailed into the at least one of the one or more nailable formworks, wherein the first construction element comprises a first wall, a first retaining wall, a first beam, or a first column. 
     
     
         17 . The concrete slab of  claim 14 , further comprising an internal nailable formwork partitioning the defined area, and wherein two or more sides of the internal nailable formwork are in contact with the second concrete composition. 
     
     
         18 . The concrete slab of  claim 17 , further comprising a second construction element nailed into the internal nailable formwork, wherein the second construction element comprises a second wall, a second retaining wall, a second beam, or a second column. 
     
     
         19 . The concrete slab of  claim 14 , wherein the concrete slab is substantially level. 
     
     
         20 . A method of assembling a construction, the method comprising:
 providing the concrete slab of  claim 14 ;   nailing a construction element into at least one of the one or more nailable formworks.