Method of molding a building structure by spraying a foamed plastic on the inside of an inflatable form

Abstract

1. A method for erecting a building structure comprising: inflating a form, .[.positioning thickness gauges within the inner surface of the form, said thickness guages being preformed from a plastic foam material,.]. spraying a .[.n additional quantity of the same.]. plastic foam material against the inside of the form to build up a .[.layer having a thickness determined by the thickness gauges which become integral with the.]. layer, .[.and.]. allowing the plastic foam to harden and become rigid and self-supporting .[...]. .Iadd.and coating the inside of the layer of foam with a layer of concrete..Iaddend.

The invention is claimed as follows: 
     
       1. A method for erecting a building structure comprising: inflating a form, .[.positioning thickness gauges within the inner surface of the form, said thickness guages being preformed from a plastic foam material,.]. spraying a .[.n additional quantity of the same.]. plastic foam material against the inside of the form to build up a .[.layer having a thickness determined by the thickness gauges which become integral with the.]. layer, .[.and.]. allowing the plastic foam to harden and become rigid and self-supporting .[...]. .Iadd.and coating the inside of the layer of foam with a layer of concrete..Iaddend. 
     
     
       2. A method for erecting a structure, said method comprising laying a foundation, securing an inflatable form to the foundation, inflating the form, spraying a plastic foam material against the form from the inside thereof, .[.and.]. allowing the foam material to harden into a self-supporting layer .[...]. .Iadd.and coating the inside of the layer of foam with a layer of concrete..Iaddend. 
     
     
       3. A method for erecting a structure comprising: laying a foundation and floor structure, securing an inflatable form to the foundation, inflating the form with air pressure, spraying polyurethane foam against the form from the inside thereof to build up a self-supporting layer, .[.and.]. cutting a door opening through said form layer .[...]. .Iadd.and coating the inside of the layer of foam with a layer of concrete..Iaddend. 
     
     
       4. A method for erecting a cold storage compartment, said method comprising: laying a circular foundation and slab, securing an inflatable form of an impervious plastic sheet material to the foundation, inflating the form with air pressure, coating the inner surfaces of the form and the surface of the slab with a polyurethane foam material to create a self-supporting structure with the impervious plastic material constituting an outer skin, .[.and.]. providing a working floor surface over the coating of foam material on the slab .[...].  .Iadd.and coating the inside of the layer of foam material with a layer of concrete..Iaddend. 
     
     
       5. A method for erecting a building comprising: laying a circular foundation and slab; securing an inflatable form of impervious plastic material thereto; inflating the form with air pressure; spraying plastic foam against the inside of the form, allowing the foam to harden into a self-supporting layer; and coating the inside of the layer of foam with a layer of concrete. 
     
     
       6. A method for erecting a reinforced concrete building comprising: laying a foundation and slab; securing an inflatable form of impervious plastic material thereto; inflating the form with air pressure; spraying plastic foam material against the inside of the form, allowing the foam material to become rigid and to become a self-supporting layer; inserting a plurality of hanger devices into the layer of rigid foam material; positioning reinforcing members spaced from the layer of rigid foam material and supported by the hanger devices; and coating the inside of the layer of rigid foam material with a layer of concrete having the reinforcing members imbedded therein. 
     
     
       7. A method for erecting a structure, said method comprising: inflating a form by injecting air under pressure therein, said form permitting a continuous seepage of air to escape therethrough, placing impervious sheet material against the inner surface of the form, spraying a plastic foam material against the sheet material from inside the form, allowing the foam material to harden into a self-supporting layer, .[.and.]. removing the form from the outside .[...]..Iadd.and coating the inside of the layer of foam with a layer of concrete..Iaddend. 
     
     
       8. A method for erecting a reinforced structure, said method comprising: inflating a form by forcing air under pressure therein, said form being of material which permits air to escape by seepage therethrough, placing elongated members against the form on the inside thereof, said elongated members partially blocking the seepage of air through the form and being supported against the form by a pressure differential, spraying a plastic foam material against the form from the inside thereof and around the elongated members, allowing the foam to harden into a self-supporting layer, removing the elongated members to create channels in the hardened foam layer, and installing reinforcing members in the channels. 
     
     
       9. A method for erecting a reinforced structure, said method comprising: inflating a form by forcing air under pressure therein, said form being of material which will permit air to escape by seepage therethrough, placing elongated ballons against the form on the inside thereof, placing sheets of impervious material over the balloons and against the form on the inside thereof, spraying a plastic foam in a layer against the impervious sheets from the inside of the form, allowing the foam to harden into a self-supporting layer, removing the form, allowing voids caused by the ballons to create channels in the outer surface of the hardened foam layer, installing reinforcing members in to the channels and covering the reinforcing members with a grout. 
     
     
       10. A method for erecting a reinforced structure in accordance with claim 9 wherein the reinforcing members within the channels are covered by spraying a concrete mixture thereupon, and wherein the entire outer surface of the structure is covered with a layer of concrete which will set and harden integrally with the concrete mixture sprayed upon the reinforcing members. 
     
     
       11. A method for erecting a roof structure over walls of a building, said method comprising: securing a flexible form to walls, forcing air under pressure into the building to expand the form upwardly in an arch spanning between the walls, spraying a plastic foam material against the under surface of the form, .[.and.]. allowing the foam to harden into a self-supporting layer .[...]. .Iadd.and applying a layer of concrete against the inside of the layer of foam..Iaddend. 
     
     
       12. A method for erecting a roof structure over walls of a building, said method comprising: securing an impervious plastic form to the walls; forcing air under pressure into the building to expand the form upwardly into a curve spanning between the walls; spraying a plastic foam material against the under surface of the form; allowing the foam to become rigid and become a self-supporting layer; and spraying a concrete mixture against the under surface of the foam layer. 
     
     
       13. The method in accordance with claim 12 further comprising: inserting hanger devices into layers of rigid foam; and positioning reinforcing members spaced from the layer of rigid foam and supported by the hanger devices whereby the reinforcing members will ultimately be embedded in the concrete mixture.