Efficient and Advanced Building Composite System (ABC) and Method

Abstract

A composite building form and a related method of construction are disclosed. The building form comprises a first and second layer of basalt fibers with a layer of DCPD foam or inert material in between. Additionally, it incorporates a reactive surface that bonds to concrete. The forms can be pre-fabricated, with features that allow them to interlock, and be lightweight and easy to assemble, and can be shaped to suit various construction elements such as columns, beams, and frames. The method of use includes assembling the forms, pouring concrete, and allowing the concrete to cure, interlocking without the need for custom tools, and utilizing color-coded parts for ease of assembly and inspection. One embodiment also involves a waterjet or router for cutting the forms, prefabricated composite material for archival designs and a reactive material for faster and easier construction. Applications of the one embodiment might include facilitating construction efficiency, waste reduction, reinforcing structures, and minimizing requirements for heavy equipment. Innovation is further reflected in the advanced computer-aided design (CAD) and manufacturing (CAM), reinforced with strong basalt composite material, high-speed assembly of complex shapes and advanced form reusability strategies.

1 . A composite building form, comprising:
 a first layer of basalt fibers;   a layer of dicyclopentadiene (DCPD) foam or inert material disposed between the first layer of basalt fibers and a second layer of basalt fibers; and   a reactive surface on the first and or second outer layer of basalt fibers that bonds to concrete.   
     
     
         2 . The composite building form of  claim 1 , wherein the first and second layers of basalt fibers are mechanically separated to provide thermal and acoustic insulation wherein the layer of DCPD foam or inert material is disposed between the first and second layers of basalt fibers. 
     
     
         3 . The composite building form of  claim 1 , wherein the reactive surface on the fibers is a pozzolan coating. 
     
     
         4 . The composite building form of  claim 1 , wherein the composite material further comprises a layer of glass fibers or carbon fibers. 
     
     
         5 . The composite building form of  claim 1 , wherein the composite building form is shaped to form a column, a pillar, floor decking, a beam, pour stop, stairs, window frame, door frame or mesh or other regular geometry. 
     
     
         6 . The composite building form of  claim 1 , wherein the composite building form is prefabricated, lightweight, and easy to assemble. 
     
     
         7 . The composite building form of  claim 1 , wherein at least one form, comprises a composite material including basalt, glass, carbon, or other fibers, and a reactive surface that bonds to concrete. 
     
     
         8 . A method of constructing a building, comprising:
 assembling a plurality of composite building forms according to  claim 1 ;   pouring concrete into the composite building forms; and   allowing the concrete to cure.   
     
     
         9 . The method of  claim 8 , wherein the forms interlock without custom tools and remain in place after pouring concrete, reinforcing a structure and protecting the structure, and wherein the forms are assembled using color-coded parts, diagrams, or digital twins. 
     
     
         10 . The method of  claim 8 , wherein the composite building forms are interlocked without the need for custom tools. 
     
     
         11 . The method of  claim 8 , wherein the composite building forms are color-coded. 
     
     
         12 . The method of  claim 8 , further comprising cutting the composite building forms to size and feature using a waterjet or router. 
     
     
         13 . The method of  claim 8 , further expanding the features by forming a composite building structure with concrete poured into the composite building with molded interlocking features that remain in place during and after the curing process. 
     
     
         14 . The method of  claim 8 , wherein at least one composite building form comprises a composite material including basalt, glass, carbon, or other fibers, and a reactive surface that bonds to concrete. 
     
     
         15 . The method of  claim 8 , wherein the composite building forms interlock without custom tools, wherein the forms remain in place after pouring concrete, reinforcing the structure and protecting the structure. 
     
     
         16 . The method of  claim 8  where the composite building forms and spacers can be interlocking and allow precise spacing and integration of cables, pipes, conduits and other features allowing rapid assembly of piping systems, electrical systems and other features. 
     
     
         17 . The method of  claim 8 , wherein the composite building forms are assembled using color-coded parts, diagrams, or digital twins. 
     
     
         18 . The apparatus of  claim 1 , comprising a composite material prefabricated to a specific building design and shipped to a building location for assembly. 
     
     
         19 . The apparatus of  claim 1 , wherein the composite material is made of a combination of two or more materials, including but not limited to metals, polymers, and ceramics. 
     
     
         20 . The apparatus of  claim 1 , comprising a mesh, form, composite structure or geogrid made of basalt or glass fiber sized to snap into place, with a pozzolan coating to enhance a pull-out resistance in concrete or geopolymer binder.