Floor and roof construction
A construction system for floors and/or roofs includes a foam form configured to engage one or more beams. When the form engages the beams, the form is further attached and secured by an attachment system. Other attachment and support components are added to the form and/or beam. Concrete is poured onto the form to create one distinct monolithic unit.
This application claims priority to U.S. Provisional Patent Application No. 60/809,624, filed May 30, 2006, entitled, “Floor and Roof Systems and Methods,” which is incorporated herein by reference. In addition, the present application is related to U.S. patent application Ser. No. ______, attorney docket no. 1006.U02, entitled “Exterior Wall Construction,” filed May 29, 2007; U.S. patent application Ser. No. ______, attorney docket no. 1006.U03, entitled “Interior wall Construction,” filed May 29, 2007; and U.S. patent application Ser. No. ______, attorney docket no. 1006.U04, entitled “Column and Beam Construction,” filed May 29, 2007.
BACKGROUND OF THE INVENTION1. The Field of the Invention
This invention relates generally to construction materials. More particularly, embodiments of the present invention relate to construction materials using expanded polystyrene.
2. Related Technology
Polystyrene, a polymer discovered in the nineteenth century, is a highly useful material having a wide variety of applications that is manufactured for use in numerous commercial enterprises. One of the most common uses of polystyrene, however, is expanded polystyrene, which is used for making such products as packing material, craft and model materials, and take-away food cups and containers.
In addition to these uses, expanded polystyrene is one of several foams used in making insulated panel building materials. These building materials, also referred to as insulated concrete forms, are used to form molds for use in constructing walls of buildings. Most commonly, an insulated concrete form for a portion of wall is set in place and the concrete is then poured into the insulated concrete form. The form then remains in place, where it acts as insulation both for curing the concrete and as general insulation for the building or structure being constructed.
Using foams for building construction provides numerous benefits. For example, foams serve as excellent insulators helping to reduce energy costs. Foams also provide superior sound absorption and their use contributes to fast construction of buildings, thereby creating competitive costs for using foams when compared to conventional building methods such as wood framing. These benefits have led to increased use of foams in building certain portions of buildings, such as exterior walls built using insulated concrete forms.
Although foams are used extensively in manufacturing insulated concrete forms for exterior walls of buildings and other structures, use of foams for other building systems and materials is not widespread. What is needed are systems and methods for configuring expanded polystyrene for interior walls of buildings and other structures.
BRIEF SUMMARY OF THE INVENTIONEmbodiments of the present invention relate to systems and methods for constructing floors and/or roofs of structures. A construction system includes a form configured to engage one or more beams. In one embodiment of the invention, the attachment of the form to the beams is secured and maintained by an attachment system that includes anchor pins and attachment and support stands. In addition to cooperating with anchor pins to secure a form to a beam, attachment and support stands engage rebar. In one embodiment of the invention, rebar is also engaged by a rebar support attached to the form. Concrete is poured onto the form, covering components attached to the form, to create one distinct monolithic unit, thus minimizing the structural discontinuities of the concrete and enhancing the strength of the structure.
These and other aspects of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
To further clarify the above and other aspects of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings are not drawn to scale. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
Embodiments of the present invention include floor and roof construction systems and methods. In one embodiment of the invention, a foam form is configured to include openings to engage beams, conduits for electrical or other utility lines, and cavities for ductworks. When the form engages the beams, an attachment system secures the form to the beams. Other components of the floor and roof system are attached to or otherwise placed in connection with the form for a variety of purposes. In one embodiment of the invention the system is completed when concrete is poured over the form and cooperating components to form one distinct monolithic unit. The floor and roof construction system of the present invention thereby provides an efficient construction system that in a floor and/or roof with minimal structural discontinuities.
With attention now to
While
As mentioned previously, certain features of form 100 are, in one embodiment of the invention, configured to allow two or more forms to be secured to each other when the forms are positioned adjacent to each other. For example, in one embodiment of the invention flanges 106 and 110 include a protruding portion 112 and a receiving portion 114, respectively. When two forms are positioned adjacent each other in a side-by-side arrangement, receiving portion 114 of flange 110 engages protruding portion 112 of flange 106, thus securing a second end of a form, such as second end 108, to a first end, such as end 104, of another form. Configuring two forms adjacent each other in a side-by-side arrangement, as described above, creates a depression between the center portions of the forms where the flanges of the forms meet.
To further engage an adjacent form, form 100 also includes elongated protruding portion 116. Elongated protruding portion 116 extends from first end 104 through center portion 102 to second end 108. In one embodiment of the invention an opposite, or back, side of form 100 (not shown) includes an elongated receiving portion also extending from first end 104 through center portion 102 to second end 108, the receiving portion being configured to engage an elongated protruding portion, such as elongated protruding portion 116. When a second form is configured adjacent to form 100 in a front-to-back arrangement, elongated protruding portion 116 engages an t elongated receiving portion of the second form (not shown).
In addition to elongated protruding portion 116, form 100 also includes a cavity 118. In one embodiment of the invention cavity 118 is configured to house ductworks. Moreover, in another embodiment of the invention form 100 includes conduits 120 for utility lines. Also, form 100 includes openings 122 and 124 configured to engage beams (shown in
Finally, in yet another embodiment of the invention, form layer 126 is configured to engage center portion 102 of form 100 at the top of center portion 102. Form layer 126 may be configured of any height, and, when added to form 100, increases the overall height of form 100. In this way form 100 may be configured and designed to have any desirable height.
Directing attention now to
Moving to
In operation, beam 200 is attached to temporary shoring. A foam form, such as form 100 described with reference to
While
In another embodiment of the invention, anchor pin 304, like anchor pin 302, also engages a form and a beam. Unlike anchor pin 302, however, anchor pin 304 is inserted into a beam from the bottom, entering the form after passing through the beam. Anchor pin 304 includes flange 310, which secures anchor pin 304 at the bottom of a beam and prevents anchor pin 304 from passing through the beam and the form. In addition, anchor pin 304 includes a top portion 312, which, in one embodiment of the invention, may be threaded. A disk, such as disk 314, is configured to engage anchor pin 304 at top portion 312 with hole 316, thus further securing anchor pin 304 to a form and a beam. In one embodiment of the invention where top portion 312 is threaded, hole 316 is also threaded. In another embodiment of the invention hole 316 is configured to include a nut.
As suggested by the preceding discussion, anchor pins 300 include an exemplary structural implementation of a means for anchoring a form to a beam. Generally, such means serve to secure a form to a beam and to prevent movement of the form with respect to the beam. Yet other examples of a means for anchoring a form to a beam include any other part of, or attachment to a floor and/or roof construction system that anchor and secures a form to a beam.
Attachment and support stand 350, shown in side view
While attachment and support stand 350 may be made of made of different materials, it may also be configured in different ways. In one embodiment of the invention attachment and support stand 350 includes a top portion 352 having a depression 354, and a bottom portion 356. In one embodiment of the invention depression 354 is cross-shaped or x-shaped. Depression 354 is configured to engage rebar. In one embodiment of the invention two rebar may be positioned in depression 354, such that the first rebar is configured orthogonal to the second rebar. Extensions 360, shown in
As shown by the discussion of attachment and support stand 350, attachment and support stand 350 is one exemplary structural implementation of a means for engaging an anchor pin or other structure that attaches a form to a beam. Generally, such means for engaging cooperate with a means for attaching to provide security and stability to a form configured to attach to a beam. Yet other examples of a means for engaging include any part of, or attachment to a floor and/or roof construction system that engages a means for attaching to further secure the means for attaching to the form and the beam.
In addition to top portion 352 and depression 354, attachment and support stand 350 includes hollow center portion 358 that extends from the center of top portion 352 through bottom portion 356. In one embodiment of the invention, center portion 358 is configured such that anchor pins 300 may be inserted through center portion 358. When attachment and support stand 350 is positioned on top of a form, one of anchor pins 300 may be inserted through center portion 358 and a form to engage a beam. Rebar may then be positioned in top portion 352 of attachment and support stand 350. Thus, attachment and support stand 350 cooperates with anchor pins 300 to secure a form to a beam, and further provides a system for supporting rebar. Embodiments of attachment system 300 are discussed in further detail below with reference to
As suggested by the preceding discussion of
In one embodiment of the invention, an anchor base plate (not shown) further secures a form to a base structure. In one embodiment of the invention the anchor base plate is configured of steel. Moreover, the anchor base plate may include multiple studs having different heights depending on design needs. The anchor base plate is configured alongside a beam to engage and secure a form coupled to one or more beams.
With attention now to
As suggested by the preceding discussion of
Directing attention now to
With attention now to
While each of forms 602 and 604 may include a top layer, such as layer 616, each of forms 602 and 604 may also include cavities 618, conduits 620, and openings 622. In one embodiment of the invention cavities 618 provide space for ductworks while conduits 620 are configured for utility lines. In another embodiment of the invention openings 622 are configured to engage beams 624 of form 602, and beams 626 and 628 of form 604. Form 604 also includes attachment systems 630 and 632, which include attachment and support stands 634 and 636, respectively. Attachment system 630 further includes anchor pin 638, while attachment system 632 includes anchor pin 640.
Embodiments of construction system 600 further include rebar support 642 positioned to engage a center portion of form 602 and a center portion of a form (not shown) that may be placed adjacent to form 602, with a center portion of rebar support 642, including notch 644, lying within depression 612. Finally, in one embodiment of the invention one or more grade pins (not shown) may also be attached to forms 602 and 604.
In operation, construction system 600 is configured as forms 602 and 604 are positioned adjacent to each other in a side-by-side arrangement, with flanges 606 and 608 engaging each other. Depression 610 is thus created between forms 602 and 604, over flanges 606 and 608. Forms 602 and 604 are further configured to engage beams 624, and beams 626 and 628, respectively. In one embodiment of the invention attachment systems, such as attachment systems 630 and 632, may further secure form 604 to beams 626 and 628.
Beams 626 and 628 are secured to form 604 as attachment and support stands 634 and 636 are positioned on top of form 604. Anchor pin 638 is inserted through attachment and support stand 634, passing through form 604 to engage beam 626. In one embodiment of the invention, a shown in
Further, rebar 646 may be positioned in top portions of attachment and support stands 634 and 636. In one embodiment of the invention two rebar may be positioned at a 90° angle within a top portion of attachment and support stands 634 and 636. Rebar 648 may also be placed in notch 644 of rebar support 642, which maintains the position of rebar within the depression and ensures an even elevation of the rebar within depression 612. In one embodiment of the invention where layer 616 is configured on top of form 602, rebar support 642 is configured to engage form 602 beneath layer 616.
Finally, construction system 600 is completed as concrete is poured onto forms 602 and 604, with concrete covering attachment and support stands 634 and 636, and rebar 646 and 648. Concrete also fills depressions 610 and 612, located between adjacent forms. In one embodiment of the invention the concrete is poured onto forms 602 and 604 in a single event. The concrete of construction system 600 is, therefore, one distinct monolithic unit. Embodiments of the present invention thereby create a construction system for floors and roofs that is easy to assemble and efficiently designed. Moreover, embodiments of the present invention provide construction systems for floors and/or roofs in which the concrete of the system is one distinct monolithic unit, thus minimizing structural discontinuities in the floor and/or roof. Further, embodiments of the present invention may be used in conjunction with other construction systems to create structures wherein concrete deposited in the structures is one distinct monolithic unit having minimal structural discontinuities.
With attention now to
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims
1. A construction system for floors and roofs comprising:
- one or more form comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene;
- one or more beams engaged by the one or more forms;
- means for securing the one or more beams to the one or more forms; and
- concrete, wherein the concrete is poured onto the one or more forms creating one distinct monolithic unit.
2. The construction system as recited in claim 1, wherein the one or more forms further comprise:
- a first end having a protruding portion; and
- a second end having a receiving portion, wherein the receiving portion is configured to engage the protruding portion.
3. The construction system as recited in claim 1, wherein the one or more forms includes openings to receive the one or more beams.
4. The construction system as recited in claim 1, wherein the one or more forms includes cavities for ductworks.
5. The construction system as recited in claim 1, wherein the one or more forms includes conduits.
6. The construction system as recited in claim 1, wherein the one or more forms includes one or more layers.
7. The construction system as recited in claim 1, wherein the beams include openings.
8. The construction system as recited in claim 1, wherein the beams are comprised of one or more of: steel, galvanized steel, and, any other metal; acrylonitrile butadiene styrene, polyvinyl chloride, and, any other plastic; and, wood.
9. The construction system described in claim 1, wherein the means for securing includes a means for anchoring and a means for engaging.
10. The construction system as recited in claim 1, further comprising means for supporting rebar.
11. The construction system as recited in claim 1, further comprising rebar.
12. The construction system as recited in claim 1, further comprising one or more grade pins.
13. The construction system as recited in claim 1, further comprising anchor base plates, wherein the anchor base plates are comprised of one or more of: steel; galvanized steel; and, any other metal.
14. A floor and roof construction system comprising:
- one or more beams;
- one or more forms comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene, wherein the one or more forms is configured to engage the one or more beams;
- an attachment system, wherein the attachment system secures the one or more beams for the one or more forms; and
- concrete, wherein the concrete is poured onto the one or more forms to create one distinct monolithic unit.
15. The construction system as recited in claim 14, wherein the one or more forms includes one or more layers.
16. The construction system as recited in claim 14, wherein the one or more forms sections include protruding ends and receiving ends, wherein the receiving ends are configured to engage the protruding ends.
17. The construction system as recited in claim 14, wherein the one or more forms include cavities for ductworks.
18. The construction system as recited in claim 14, wherein the one or more forms include one or more conduits.
19. The construction system as recited in claim 14, further comprising:
- a rebar support configured to engage a center portion of the form; and,
- rebar positioned within the rebar support.
20. The construction system as recited in claim 14, wherein the attachment system further comprises:
- one or more attachment and support stands; and
- one or more anchor pins, wherein the one or more anchor pins is configured to be inserted through an opening in the one or more attachment and support stands to secure the one or more forms to the one or more beams.
21. The construction system as recited in claim 20, wherein the one or more attachment and support stands is configured to engage rebar.
22. The construction system as recited in claim 14, further comprising one or more grade pins attached to the one or more forms, wherein the one or more grade pins are comprised of: acrylonitrile butadiene styrene; polyvinyl chloride; and, any other plastic.
23. The construction system as recited in claim 14, wherein the attachment system is comprised of one or more of: acrylonitrile butadiene styrene; polyvinyl chloride; and, any other plastic.
24. The construction system as recited in claim 20, wherein the one or more attachment and support stands is comprised of one or more of: steel, galvanized steel, and, any other metal; concrete; and, clay brick.
25. The construction system as recited in claim 14, further comprising a rebar support attached to the one or more forms, wherein the rebar support is comprised of one or more of: steel; galvanized steel; and, any other metal.
26. The construction system as recited in claim 25, further comprising one or more rebar, wherein the rebar support and the attachment and support stands engage the one or more rebar.
27. A floor and roof construction system comprising:
- one or more beams, wherein the one or more beams include openings;
- one or more forms configured to engage the one or more beams, the one or more forms further configured to be positioned adjacent to each other with one or more receiving ends of the one or more forms configured to engage one or more protruding ends of the one or more forms, the one or more forms comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene, wherein the one or more forms further comprises: one or more cavities within the one or more forms for receiving ductworks; one or more conduits within the one or more forms for receiving utility lines; one or more layers configured to attach to a top center portion of the one or more forms; and
- an attachment system for attaching the one or more beams to the one or more forms, the attachment system comprising: one or more anchor pins; and one or more attachment and support stands; and
- a rebar support configured to engage the one or more forms and further configured to support rebar;
- rebar; and
- one or more grade pins attached to the one or more forms.
28. The construction system as recited in claim 27, further comprising concrete, wherein the concrete is poured onto the one or more forms to create a monolithic unit.
29. The construction system as recited in claim 27, wherein the one or more beams are comprised of one or more of: steel, galvanized steel, and, any other metal; and, wood.
30. The construction system as recited in claim 27, wherein the one or more beams, the one or more anchor pins, the one or more attachment and support stands, and the one or more grade pins are comprised of one or more of: acrylonitrile butadiene styrene; polyvinyl chloride; and, any other plastic.
31. The construction system as recited in claim 27, wherein the one or more anchor pins are one or more of: barbed; and, flanged.
32. The construction system as recited in claim 27, wherein the one or more anchor pins further comprise anchor disks configured to attach to a first end of the one or more anchor pins.
33. The construction system as recited in claim 27, wherein the one or more attachment and support stands engage a first end of the one or more anchor pins.
34. The construction system as recited in claim 27, wherein the one or more attachment and support stands engage the rebar.
35. The construction system as recited in claim 27, wherein the one or more attachment and support stands are comprised of one or more of: steel, galvanized steel, aluminum, and any other metal; concrete; and, clay brick.
36. A method for constructing floors and roofs comprising: and any width, wherein the one or more forms is comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene;
- configuring one or more one or more forms sections to create a one or more forms having any length
- attaching the one or more forms to beams;
- arranging components on and within the one or more forms; and
- pouring concrete onto the one or more forms to create a monolithic unit.
37. The method as recited in claim 36, wherein the attaching the one or more forms to beams further comprises:
- inserting a means for anchoring into the one or more forms and the beams; and
- coupling a means for engaging to the means for anchoring.
38. The method as recited in claim 36, further comprising:
- gauging a depth of the concrete; and
- ensuring a grade of the concrete is even.
Type: Application
Filed: May 29, 2007
Publication Date: Dec 6, 2007
Inventor: Guy L. Marker (Hyrum, UT)
Application Number: 11/807,656