Abstract: Generally mat shaped concrete construction units provide novel, versatile building materials particularly for flexible multi-ply concrete composites in pavement or floor construction, roadbeds, driveways, waste disposal sites, etc. The mat-like structures comprise an outer shell subdivided into parallel tubular compartments which are filled with dry concrete mix so as to provide controlled chemical hydration for greater strength and durability. The multi-ply structures fabricated with the concrete construction units exhibit enhanced resistance to fracturing and possess residual structural values not found in equivalent poured concrete structures.

Abstract: A pipe attachment device (12, 52) for attaching a pipe (16, 54) to a concrete form wall (14) includes an axially extending wall (12, 54) and a floor (24, 58) extending laterally from a first end of the axially extending wall. The floor is affixed to the concrete form and the pipe to be held in place on the form is pressed on the axially extending wall. The pipe is held thereon by the friction of a force fit. After concrete is poured into the form wall and allowed to cure, the pipe attachment device is removed with the concrete form wall while the pipe is allowed to stay embedded in the wall. A separate riser (20) is adhered to the outer surface of a standard pipe (16) to prevent it from sliding out of the concrete once the form is removed. A special pipe coupler (54) can be used with a male pipe attachment device having a built in shoulder (68) and riser (64). Intumescent cuffs (18, 56) can be used with either the standard pipe or the special pipe coupler.

Abstract: A reinforced fiberboard box for creating a void in and under concrete formations. A single piece of double faced, corrugated fiberboard is defined by a face, a bottom, a pair of end flaps, and a pair of side flaps. The end flaps are folded into at least four uniformly shaped partitions which are subsequently folded onto the face of the fiberboard and are aligned along the longitudinal axis to create a box-like structure. Pairs of side flaps are then wrapped around the sides and top of the partitions to form a completely closed, internally reinforced, box-like structure. A portion of the side flaps are tucked inwardly, intersecting the partitions so that slots in the side flaps interlock with slots in the partitions which prevents the box void from unfolding during use.

Abstract: A panel for modular construction of building walls and the like which comprises a flat insulating core which includes a multiplicity of air-filled shell-like cavities in a staggered matrix of layered sheets which are separated from each other by a binding filler material. The core is surrounded and captured by a rigid rectangular frame having identical side members and identical end members which are contoured and oriented so as to engage the opposing side and end members of adjacent panels so as to align and fasten the panels to each other in assembly. Resilient sealing means are disposed between side and end rails of adjacent panels for forming an air-tight barrier across the assembled panels. The core is covered by facing layers of cement and gypsum construction for providing building exterior and interior wall surfaces respectively. A vapor barrier is sandwiched between layers of gypsum construction.

Abstract: A cementitious panel is provided with spaced inner and outer surfaces connected by edge surfaces. A waterproof film forms longitudinally extending cavities within the panel, with the cavities being laterally spaced from each other and spaced from the inner, outer and edge surfaces of the panel. Expanded lightweight, inert granular material substantially fills the cavities, and a suitable film closes off the ends of the cavities.When necessary or desirable, the panels are temporarily secured in position adjacent a member and in end to end relation to enclose it and provide fire protection. Holes are drilled through the panels at predetermined locations, and metal studs are inserted through the panel to contact the enclosed metal member and the stud is the welded to the member so that the end of the stud projects outwardly beyond the panel surface. The panels are then secured to the stud end projecting therethrough to enclose and provide fire protection to the member within the positioned panels.

Abstract: Relatively lightweight precast building panels for use as wall, roof or floor sections are provided. Each panel is molded in a form which is generally rectangular in configuration and provides a cavity into which concrete is poured, the floor of the form being comprised of a plurality of recessed styrofoam inlays separated by wood strips such as furring strips which are also used as a separation between the entire inside perimeter of the form and the styrofoam inlays. After the styrofoam inlays and wood strips are placed, concrete is poured into the form and finished off in the conventional manner. The side walls of the form are removed after the cement sets up and there results a concrete building panel with an adhered styrofoam coating permanently bonded over one surface with wood strips around the perimeter thereof and between each pair of styrofoam inlays.

Abstract: An anchoring track designed to be embedded in the surface of a structural member of concrete, the track having a C-shaped profile and a styrofoam filler body filling out the interior of the track to prevent the penetration of mortar into the track, the filler body being removable from the embedded track by means of a tear strip which is arranged between the back side of the filler body and the base wall of the anchoring track, in alignment with the slot of the anchoring track. The tear strip, when pulled through the slot of the track, tears out a central profile portion from the filler body to permit easy removal of the profile portions of the filler body remaining underneath the flange portions of the anchoring track.

Abstract: Described in a displacement body for forming cavities in concrete structures. The displacement body lends itself to simple and cost-effective production, is extremely light-weight and still capable of meeting stability requirements. In a preferred embodiment the displacement body consists of a grid structure (1) formed of intersecting longitudinal and transverse rods, and plastic sheets (2a, 2b) applied to both sides of the grid structure and connected to one another and to the grid structure by welding and/or heat-shrinking. Further described are structures formed under employ of such displacement bodies, as well as advantageous methods for making same.

Abstract: A box beam reinforced concrete and steel construction providing spaced apart wire mesh reinforced concrete skin walls and interior concrete supporting frangible sheets providing for solid concrete cores contiguous to and monolithically integrated with the skin walls.

Abstract: An inexpensive, insulated, upright wall, ceiling, floor or roof, made of panels fastened together at panel edges. Each panel has a can backing and supporting element (preferably masonite, but alternatively plywood, plastic, metal lath or the like), panel-reinforcing bars connected to edges of the can-backing element, a plurality of layers of randomly-placed cans on the can-backing element and within the bars, and a can supporting and stabilizing element on the side of the cans opposite to the can-backing element. Saving labor of more careful arrangement of the cans, and increasing the strength against breaking of the panel, they are heterogeneously dumped into the frame of the bars and the can-backing element; and preferably the frame is shaken to somewhat settle the cans in it. In further stabilization of the cans in place, preferably porous, insulating concrete material, or foamed concrete, or foamed polyolefin plastic material is placed on top of the assembled cans.

Abstract: A composite building module and method for making same including forming a bottom layer of fiber reinforced wet cementitious material, placing at least two rigid foam cores side by side on the bottom layer with the adjoining edges configured to define a channel around adjoining cores and encapsulating the cores in a fiber reinforced wet cementitious shell by depositing fibers on cementitious material around the sides of the cores and on the top thereof, wherein each channel is filled in to form a rib around the interior of the cementitious shell.

Abstract: A wall unit having a vapor-proof evacuatable envelope and a supporting core in the envelope. Wall shells form the outer sides of the element, and screw means extend through and rigidly interconnect the wall shells and thus the element, the screw means having flanges which can be adjusted toward or away from each other to adjust the pressure applied to the wall element by the screw means. Horizontal and vertical reinforcement means are pre-stressed and cast in the outer wall shell.

Abstract: A reinforced insulated concrete building panel has an inner layer of concrete and an outer layer of concrete, with a layer of insulating material sandwiched therebetween. Shear connectors are embedded in the layer of concrete and extend from the outer layer through the layer of insulation and into the inner layer to prevent delamination of the panel during handling. The shear connectors have projecting portions defining a depth gauge to indicate when the connector has been inserted a proper distance into the panel during construction of the panel.

Abstract: A liner for concrete forms and method for making poured concrete walls comprises a liner body constructed of insulative material and shaped for positioning between a pair of interconnected form panels. The liner body has opposing sides, one of which is positioned abutting an interior surface of a first one of the panels. The other side of the liner body as a textured, decorative surface spaced from the other panels, and is contoured for molding concrete poured therebetween. A plurality of similarly shaped liner bodies are placed in a side-by-side relationship along the interior surface of each section of form panels, with the textured surface of each oriented inwardly. Unsolidified cementitous material, such as concrete, is poured into the cavity having a single insert therein or formed between opposing inserts, and is cured to a solidified state.

Abstract: A block used for forming reinforced concrete structures employs a number of thin-wall tubes supported in spaced parallel relationship to one another. The upper and lower ends of the tubes are supported by laterally extending sheet metal frames which leave the tube ends open. The upper frame has an upward opening channel shaped cross-section. A pair of wall panels which form the inner and outer wall surfaces of the completed structure sandwich the tubes and extend between the frames. The volume between the panels, exterior of the tubes, is filled with a lightweight thermal insulation. In the completed structure, the tubes are filled with reinforced concrete to form the columns for the structure and interconnected by horizontal reinforced concrete bond beams poured in the upper frame members.

Abstract: An upright-wall, ceiling or roof made of panels fastened together along contacting panel edges. Each panel is made of a can-supporting planar element (a sheet of plywood, masonite, plastic or the like), reinforcing bars defining outer edges of the panel, cans between the reinforcing bars, wide-mesh wire or plastic panel-reinforcing network on the cans, and molded matrix material (foamed, cellular, polyolefin plastic, or concrete of portland or other cement and sand or porous aggregate -- for example, cinders, vermiculite, pumice, charred sawdust or the like) on the cans. The can-supporting element is placed in a mold, cans are put on this element optionally parallel to it but with their axes preferably perpendicular to it, the wide-mesh network is placed on the cans, and the moldable plastic material in fluent form is poured or injected into the mold thru the wide mesh of the network around the cans and on the network.

Abstract: A sheet metal structural shape for use as a stud or mullion in wall construction or a purlin or sub-purlin in deck construction which is symmetrical about a vertical bisecting plane having a central vertical web, two diagonal legs projecting downwardly from one end of the web forming an included angle of about 30.degree. to about 90.degree., each of the diagonal legs having a leg projecting downwardly at its extremity in a plane substantially parallel to the web, each of the parallel legs having flanges extending outwardly at their extremity, a closure side extending between the extremities of the flanges enclosing the area formed by the diagonal sides, parallel sides and closure side, and a stiffening member at the other end of the web. A wall structure utilizing a spaced series of the metal structural shapes with a wall material attached to the flanges of adjacent structural shapes.

Abstract: A plastic foam core concrete plank and the method of making same is described which employs foamed plastic core forming members positioned on an initial layer of concrete in a forming pallet and held translationally and vertically in position relative to the initial layer of concrete as a top layer of concrete is poured into position around and over the core members to complete the slab. The core members have a plurality of discontinuous recesses extending from one surface thereof which are exposed to the lower or initial layer to create voids in the slab for light construction and to decrease the thermal transmissions therethrough.

Abstract: A roofing shingle consisting of an upper layer of composition roofing material, a lower layer of waterproof roofing felt, and an intermediate layer spacing the upper and lower layers apart, all of the layers being firmly bonded together. The intermediate layer may function to provide a dead-air space for purposes of heat insulation, or may consist of tubular members permitting free circulation of air between the upper and lower layers. The composite structure of the shingle gives it a bending strength highly resistant to curling or other damage by high wind, and the lower layer may be extended to underlie adjacent shingles in the same course, so as to provide a waterproof under-layer for the upper layers.

Abstract: An insulated bar or panel, usable in walls, ceilings-floors or roofs, including new or used cans of metal, glass or plastic, preferably having lengths less than twelve times their diameters, containing insulation (preferably inexpensive insulation such as loose earth, pumice or crushed lava, tanbark, small lumps of pine or other bark, slightly charred sawdust, bits of charcoal or coke, preferably preservative treated cottonseed or rice hulls or the like, cotton linters or bolls, tufts of cotton or rockwool, or vermiculite). The cans, which for example may be of paint-containing or coffee-containing type, are end-joined in a line. They are imbedded in a shape-holding matrix of plastic material (preferably porous, foamed plastic or porous concrete of portland, epoxy or other cement, mixed with lightweight aggregate, thus forming a strong, elongated bar or panel.

Abstract: The composite wall element of this invention comprises an insulating wall element arranged within or inserted into an outer, pressure resistant, preferably load bearing wall element which completely encloses the former. Within the inner insulating wall element and/or the cavity within the outer wall element a substantially dry gas atmosphere and preferably air atmosphere is established and maintained under subatmospheric, atmospheric, or superatmospheric pressure. Such novel composite wall elements are superior in their thermal and/or acoustic insulation properties to heretofore known structural elements.