PRE-SHAPED FORM CONSTRUCTION COMPONENTS, SYSTEM, AND METHOD OF CONSTRUCTION USING THE SAME
A building component includes a form that is pre-shaped. The form includes a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment is between the channel segment and the corresponding channel segment, and when respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel is created between the form and the corresponding form. Further, when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel is created between the form and the corresponding form.
This disclosure relates to pre-shaped forms as building components used for building construction. More particularly, the pre-shaped forms are pre-manufactured building components such as wall panels, column and beam structures, ceiling and floor panels, footing structures and panels, stair structures, and corner forms. These components provide for fast and efficient building erection, improved strength, durability, weight, and energy efficiency characteristics, and are highly customizable by craftsman of medium skill.
Related ArtWall panel systems comprised primarily of concrete suffer from many inherent defects including: poor thermal characteristics, high costs to manufacture and install, poor fire and wind resistance, added weight stress requirements for a building's foundation, etc. In general, concrete wall panel systems rely solely on the panel and/or structural support members integrated therein for strength.
Attempts have been made in the industry to decrease the weight and improve the strength of the individual panels by adding metal studs or similar support members, and/or by using concrete material. While such reinforced conventional panels have some benefits, the metal studs provide poor insulative qualities in cold climates due to the high heat transfer associated with the metallic studs. Furthermore, embedded metallic studs and nails make onsite customization dangerous and difficult.
In other conventional modular panel systems, attempts have been made to create a lightweight building panel that withstands expected loads and provides high insulation characteristics. However, these conventional panels generally implement a plurality of metal and carbon components to construct, thus reducing or eliminating the ability to fully customize the panels on the jobsite due the challenges and inherent risks of cutting through such obstacles. Additionally, any onsite modifications could compromise the strength and integrity of the conventional panel systems, as the strength of the system is greatest when each panel remains intact as one cohesive unit. Furthermore, as the conventional panels are constructed primarily out of a lightweight insulative material, they lack the fire protection that a panel made mostly of a lightweight cementitious material offers. Therefore, having a panel system that is both customizable onsite while also providing a higher fire rating is desired.
Additionally, a primary aim of conventional panels has been to lower the cost of modular panel systems. However, due to the series of components that are required for each panel, the end result is a panel that still has relatively high manufacture costs. The high cost prevents most new building owners, especially in the residential market, from using the conventional panel systems. Thus, a strong, lightweight panel that is less expensive to manufacture and that is economical to construct in residential and commercial markets is desired by many in the construction industry.
It is contemplated that cellular concrete may be useful in construction. However, attempts using conventional methods are cost prohibitive and/or lack in structural strength. Cellular concrete has many names, but essentially the expression “cellular concrete” (often referred to as aerated concrete) denotes a material expanded further to the presence of small bubbles into the concrete mixture during its setting, which will confer porosity to the final cured material. Due the presence of the bubbles, cellular concrete is often considered to be “lightweight,” “enlightened,” “porous,” or “air-entrained,” in comparison to conventional concrete materials, i.e. the resulting cellular concrete material has a lower density than a conventional concrete material.
Some characteristics of cellular concrete with respect to its use as a building material include sound absorption, lightweight, insulative, and fire resistant.
There are two common methods for forming a structure of cellular concrete—autoclaved and non-autoclaved. Autoclaved aerated concrete (AAC) utilizes steam, pressure, and/or heat to cure the cellular concrete resulting in greater strength than the non-autoclaved method. However, the inherent costs in manufacturing using this method make it more expensive than many other building materials, including non-autoclaved cellular concrete. Furthermore, the AAC panels do not follow the innovative column and beam approach as outlined in this invention. The non-autoclaved method utilizes a foaming agent and other ingredients without baking the cellular concrete with heat and steam. This method is less expensive to manufacture but lacks the structural strength of AAC, and results in limitations to the size of the panel that can be used in construction—the basic size typically no larger than cement blocks. Some improvements have been made in increasing the strength of non-autoclaved cellular concrete by adding carbon fiber or even carbon nanotubes, among other compounds to the mix. However, a building material that combines the strength of AAC in the form of a highly customizable wall panel, while remaining less expensive to manufacture, is desired.
SUMMARYThis disclosure relates to a building component and a system of building components. The building components within a system may vary in shape, dimensions, and geometry. However, the building components all have in common the inclusion of an economically advantageous and geometrically-adaptable material. In an embodiment, the common material may include a lightweight cementious material. Using a combination of various components of varying geometries, it is contemplated that an entire building structure may be formed using the components of the system described herein.
In an embodiment, this disclosure describes a building component that may include a form that is pre-shaped and made of a lightweight cementious material. The form may have a channel segment that extends along at least a part of the form. A profile of the channel segment may be defined, at least in part, by a first portion that projects in a first direction and a second portion that projects in a second direction that is transverse to the first direction. The profile of the channel segment may be defined from a perspective of looking at the channel segment in line with a direction of extension of the channel segment. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment may be between the channel segment and the corresponding channel segment such that a beam channel or a column channel is created between the form and the corresponding form. Note, for the purposes of this document, the term “beam” may refer generally to any horizontally-oriented reinforcing structure, the formation of which may occur in a beam channel (or channel segment) of building components. Further, the term “column” may refer generally to any vertically-oriented reinforcing structure, the formation which may occur in a column channel (or channel segment) of building components.
In another embodiment, this disclosure describes a building component that may include a form that is pre-shaped. The form may include a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment may be between the channel segment and the corresponding channel segment. When respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel may be created between the form and the corresponding form. Alternatively, when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel may be created between the form and the corresponding form.
In another embodiment, this disclosure describes a method of constructing a building structure. The method may include an act of disposing a form in a position for constructing a portion of a structure. The form may be pre-shaped and made of a lightweight cementious material or a different non-cementious material. The form may include a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The method may further include an act of abutting a corresponding form having a corresponding channel segment against the form such that: the channel segment and the corresponding channel segment are aligned, and one of a beam channel or a column channel is created between the form and the corresponding form. Additionally, the method may include pouring a reinforced concrete mix into the one of the beam channel or the column channel such that the form and the corresponding form are a permanent fixture with the reinforced concrete.
The Detailed Description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items. Furthermore, the drawings may be considered as providing an approximate depiction of the relative sizes of the individual components within individual figures. However, the drawings are not to scale, and the relative sizes of the individual components, both within individual figures and between the different figures, may vary from what is depicted. In particular, some of the figures may depict components as a certain size or shape, while other figures may depict the same components on a larger scale or differently shaped for the sake of clarity.
This disclosure is directed to one or more variations of a building component (also referred to hereinafter as a “form”) and a system of building components to be used together to build a structure. The building components can be implemented in new or existing structures, either entirely with other components created by the same or similar manner of manufacture (e.g., corner forms, step forms, wall panel forms, flooring forms, ceiling forms, etc.), or with conventional construction materials (e.g., wood, reinforced concrete forms, steel, drywall, etc.). Accordingly, the building components may be integrated into an existing structure either for remodeling or adding onto the existing structure, or the building components may be used to construct the entirety of a new structure.
The building components are sturdy structural forms that may be aligned and arranged together so as to form walls, floors, ceilings, etc. The forms may also be referred to as “shuttering” or “molds.” In many embodiments, individual building components include channel segments that extend along at least a portion of a perimeter of the form. Thus, by aligning the channel segments of adjacent forms, an empty channel is created therebetween. The channels extend along and between adjacent forms and, depending on the structure being built (e.g., a vertical wall vs. a horizontal floor), the channels may be completely enclosed lengthwise or may be open on a side lengthwise while being closed by the forms on an opposite side. The channels are placed and sized between forms such that reinforced concrete can be easily poured into the channels at the time of construction. As the reinforced concrete fills the channels and subsequently hardens, columns and beams of reinforced concrete are created, and the reinforced concrete bonds to the material of the forms to provide additional strength to the structure. As such, the building components (“forms”) of the instant disclosure remain a permanent part of the structure, and the poured reinforced concrete becomes integrated into the forms.
In many instances, due to the nature of the manufacture and shape of the forms, no additional framing forms are needed to hold the forms in place prior to or during the pouring of the concrete. Thus, there is no need to strip any framing forms after the concrete is poured and cured, which saves additional time and money in both labor and material costs.
The forms are generally pre-shaped for construction in the various embodiments desired using different mold frames. Thus, the forms are ready for installation upon receipt. However, inasmuch as construction designs vary significantly for myriad reasons, onsite modifications are to be expected and indeed necessary in some situations. Further, the forms are expected to carry significant loads under normal building structure standards. Accordingly, the forms may be created from a material having several desired properties. For example, in an embodiment, the building components may be created using lightweight cementious material, such as cellular concrete. Additionally, and/or alternatively, other materials may be used to create the forms, including, but not limited to: autoclaved aerated concrete (AAC), porous concrete, lightweight concrete, low-density concrete, foamcrete, insulated concrete, aircrete, polycrete, polystyrene concrete, hemperete, and potentially other light-weight non-cement-based materials. Examples of other non-cement-based materials, that may be candidates for the building components, include those materials that exhibit comparatively similar or better property characteristics as those inherent to cellular concrete. Some of the properties to consider include: fire, wind, pest, projectile resistance; insulation value for energy efficiency purposes; strength characteristics (e.g., load bearing, tensile, compression, sheer, etc.); manufacturability (e.g., curing time, difficulty level in preparation, etc.); long term durability with respect to the environment(s) in which the forms are to be installed and expected duration of use (e.g., rot and decay resistance due to moisture, bacteria, soil, sun exposure, etc.); effect of the material on the environment (e.g., toxicity to manufacturers, environment, occupants, etc.); affordability (e.g., available resources, shipping practicalities and associated costs); and ease of installation (e.g., fast erection, customizability, varied skill-level, etc.). Alternative, non-cement-based materials may include expanded polystyrene, glass-fiber reinforced gypsum, magnesium-based compounds, or other suitable material that demonstrates a high strength-to-weight ratio.
Additionally, the material of the forms may be reinforced with carbon fiber, carbon nanotubes, wire mesh, steel, or other reinforcements common to the construction industry to provide even greater load and span capabilities, as well as increase the tensile strength, manipulability, and machinability of the building components. The size, type, and quantity of reinforcements, as well as any stabilizing agents and/or organic binder(s), may vary depending on the engineering requirements for a particular building (single story, multi-story, etc.).
Moreover, in an alternative embodiment, the form includes more than two elements. For example, a form may be manufactured by casting a planar, insulative core within cellular concrete (or other material as detailed above). Such an embodiment may provide additional thermal enhancements to the panel. The insulative core may include any type of material that is thermally efficient and has a low heat transfer coefficient, as determined by those skilled in the art.
It is further contemplated to provide building components for foundations, crawlspaces, exterior walls, interior walls, shaft walls, cladding, curtains, facades, and veneers, as well as other building components such as lintels, headers, and gables. These components may be used in load bearing and non-load bearing applications. It is also envisioned that these components may be used for fencing systems such as sound barriers, privacy fencing, landscaping fencing, as well as in-fill walls, retaining walls, etc. In some embodiments, the forms may be connected together vertically or horizontally in an end-to-end or side-to-side relationship to provide a wall of a desired length for a building.
The building component system further saves time and material by combining several construction divisions into one innovative system, such as eliminating in whole or in part framing, insulation, vapor barrier, exterior sheathing, and drywall; drywall may still be installed over the panels if desired. The building component system may further minimize the requirement for extra surface coats of heavy stucco. Eliminating various construction divisions has two additional benefits immediately apparent—drastic reduction in onsite waste and the minimization of negative impact on the environment.
An additional advantage that may be achieved with the building component system is that the structures built may have high energy efficiency. This efficiency is due, at least in part, to a combination of high R-value inherent to cellular concrete, as well as thermal mass and air-tightness. The heating and cooling costs of buildings created using the instant building component system may be greatly reduced when compared to most conventional building systems.
The forms may include colors, designs, decorative finishes, textures, patterns, carvings, profiles, and other decorative elements. Furthermore, the outer faces of the forms may be produced with a highly smooth surface for improved finishing characteristics, particularly for the interior of a building, for example, to provide a finished interior wall. The forms may be manufactured to accept multiple different types of finished exterior and interior materials such as stucco, brick, rock, siding, cladding, veneers, drywall, plaster, wallpaper, paint, carpet, trim, tile, etc. In an embodiment, a paraffin coating or covering is provided on the exterior surface during manufacturing. Other coatings may be provided, such as liquid EDPM, that serve the same purpose of preventing an excessive bond between the exterior concrete wall and the bricks, as well as reduce cracking in bricks or stone due to the variations in shrinkage of the exterior concrete panel and brick or manufactured stone. This type of coating/covering may also allow for removal of a damaged brick without excessive damage to the wall panel.
Notably, the building components may easily accept screws, nails, brackets, bolts, fasteners. This feature allows for a great amount of versatility for customization in hanging cabinets, shelves, pictures, etc. Further, the building components provide furring as an integral component to the panel should additional support be desired. The furring may be wood, plastics, metal, composites, etc. The furring may provide additional anchoring support as needed to attach such things as cabinetry, shelves, fixtures, and other building components. The furring may vary in size, location, amount, and types of material, and will typically be cast into a form during the manufacturing process. In addition, fasteners similar to those used for concrete block may be utilized for heavy loads.
In yet another embodiment, a form may include one or more utility chases. A utility chase may serve as a convenient location to route utilities such as wiring, cables, piping, ventilation, etc. Receptacle boxes may also be cast into the forms, or installed on the jobsite. Chases may also serve as channels into which dowels or reinforcement bars, such as rebar, may be inserted into the forms to tie the forms into the building foundation or into other forms of the building. A utility chase may be oriented in one or more directions and positioned either near the interior concrete face, exterior concrete face, or both.
Illustrative Embodiments of a Form as a Wall PanelIn an embodiment,
Wall panel 100 may include a panel body 102 having length “L,” a width “W,” and a thickness “t,” as shown in
A channel segment 104 is disposed in at least one side of wall panel 100. As depicted in
Despite the positioning of channel segment 104 between first side section 106 and second side section 108, first side section 106 and second side section 108 remain connected via a core 110. Wall panel 100 may be cast from a single material, such as a lightweight cementious material discussed above. In this case, first side section 106, second side section 108, and core 110 may be cast simultaneously. When cast simultaneously, channel segment 104 may be formed to a desired size during the casting or channel segment 104 may be cut into a solid cast wall panel as desired after casting. Additionally, and/or alternatively, wall panel 100 may be cast using multiple materials. For example, first side section 106 and/or second side section 108 may be cast from a lightweight cementious material, while core 110 may be of a different material, as detailed hereinafter with respect to
A shape of the periphery of core 110 may correspond to the shape of the periphery of one or both of first side section 106 and second side section 108. For example, as shown in the embodiments of
A depth “d” of channel segment 104 may vary depending on desired or required beam or channel sizes (as discussed in detail further herein). Depth d of channel segment 104 may be varied during the manufacture of wall panel 100 by casting core 110 such that one or more of the area dimensions (e.g., width and length) of core 110 are either smaller or larger as desired, thereby exposing more or less surface area of surface 114 and surface 116. Moreover, though depicted as having a substantially uniform depth surrounding wall panel 100, depth d may further vary along the length L1 of channel 104. For example, in an embodiment, depth d of channel segment 104 may vary with the distance from an edge of panel body 102. Thus, channel segment 104 may have a planar appearance when depth d remains substantially uniform across length L1; or channel segment 104 may have a concave or convex appearance when depth d rises and falls or vice versa across length L1 (not shown); or channel segment 104 may have a wavy or sinusoidal appearance when depth d rises and falls sequentially across length L1 (not shown). Such differences in shape of channel 104 may ultimately provide different strength characteristics for loads placed thereon in the reinforced concrete poured therein (not shown in
In an embodiment, respective corresponding dimensions of first side section 106 and second side section 108 may be substantially equal or may be different. In an example where the dimensions are different, while each of first side section 106 and second side section 108 is still larger than core 110, at least one of the length or width of first side section 106 may be shorter that the corresponding at least one length and width of second side section 108. Additionally, and/or alternatively, it may be desired that a thickness of one of first side section 106 and second side section 108, at the channel segment 104, is greater or lesser than the corresponding thickness of the opposing side. (See
Note, while the following discussion regarding
Additionally,
For the sake of clarity,
As indicated above,
In
In yet another embodiment depicted in
In an alternative embodiment of a corner 700B,
In another alternative embodiment forming a corner,
Further, in corner form 700C first and second core portions 748a, 748b may extend partially toward corner arm ends 752a, 752b, again leaving a gap so as to create channel segments 754a, 754b, respectively. Similar to the channel segment 104 of wall panel 100, the bounds of channel segments 754a, 754b may be defined by intersecting surfaces. For the sake of convenience and to avoid unnecessary repetition, the following description of the channel segments 754a, 754b only refer directly to reference numbers depicted at arm end 752a of the corner form 700. However, it is contemplated that one skilled in the art will recognize that the description of the surfaces labeled in channel segment 754a would likewise apply to channel segment 754b. Continuing, the bounds of channel segment 754a may be defined by: a surface 756 of core portion 748a; an interior surface 758 of first arm 744a as a first portion projecting in a direction away from (e.g., transversely to) surface 756 of core portion 748a; and an interior surface 760 of first arm 746a also projecting in a direction away from (e.g., transversely to) surface 756 of core portion 748a. As stated above, “transversely,” as used herein, may include intersecting directions of extension that differ in trajectory perpendicularly, non-perpendicularly, arcingly, or a combination thereof.
After alignment of corner arm ends 752a, 752b with respective adjacent wall panels (not shown), whereby column channels are formed, reinforced concrete may be poured into channel segments 754a, 754b to form bonded, reinforced columns between the corner form 700c and adjacent forms (e.g., wall panels, beam forms, etc.).
Illustrative Embodiments of a Form as a Flooring or Ceiling PanelIn
Moreover, flange 804 has a first thickness “t′” and body 802 has a second thickness “t″” that is different than the first thickness. That is, in an embodiment, a thickness of form 800 at channel segment 806 is less than a thickness of form 800 away from channel segment 806 (i.e. at the body 802), where the thickness is defined as a distance between a front surface and a back surface opposite the front surface of form 800.
When form 800 is installed aligned and abutted with another form (e.g., another form “800”), channel segment 806 is aligned with the corresponding channel segment of the other form, such that a surface 812 of flange 804 abuts the adjacent corresponding surface. Consequently, as shown in the incomplete flooring/ceiling structure 900 of
By aligning surface 904 of the adjacent flange in
For example, in an embodiment depicted in
As seen in an embodiment shown in
In other embodiments seen in
In
Note, despite different aspects or features being described and shown in distinct figures herein, it is contemplated that several features, though depicted herein in different figures for clarity, may be implemented within a single form without departing from the intended scope of protection for this disclosure. For example, a single flooring/ceiling panel form may include an insulative member, reinforcement members, a chase, and a mid-body beam channel. This same principle of using a variety of features in a single form may apply through any of the various building components described herein, such as the wall panel form, the corner form, the beam form, the column form, etc.
Illustrative Embodiments of a Form as a Beam FormBeam form 1600 includes a channel segment 1602 that is supported by opposing sidewalls 1604, 1606 extending from base wall 1608. As with channel segment 104 of wall panel 100, channel segment 1602 may be defined similarly by the surfaces that provide the boundaries for a beam channel of reinforced concrete integrated with beam form 1600 upon installation. That is, channel segment 1602 may be defined by intersecting surfaces, namely: a surface 1610 of base wall 1608; an interior surface 1612 of sidewall 1604 as a first portion projecting in a direction away from (e.g., transversely to) surface 1610 of base wall 1608; and an interior surface 1614 of sidewall 1606 also projecting in a direction away from (e.g., transversely to) surface 1610 of base wall 1608. In an embodiment, one or both of surface 1612 and surface 1614 project (or extend) transversely to surface 1610. Note, “transversely,” as explained above, may include intersecting directions of extension that differ in trajectory perpendicularly, non-perpendicularly, arcingly, or a combination thereof. Thus, beam form 1600 includes a first side that is convex and a second side that is concave, and the channel segment 1602 extends along the concave second side.
Inasmuch as beam form 1600 may be combined consecutively with additional beam forms (not shown), beam segment 1602 may itself form a portion of the installed “beam channel,” or, in a case where beam form 1600 is long enough for use in a space by itself (without aligning with other beam forms), reference number 1602 may be referred to as simply the “beam channel” since it is not merely a “segment” of the ultimate channel.
In
Illustrated in
Illustrative Embodiment of a Method of Constructing a Building with Forms
Method 2302 may continue with act 2306, in which a structural reinforcement member may be aligned with at least one of the form or the corresponding form, or within the at least one of the beam channel or the column channel. In act 2308, a reinforced concrete mix may be poured into the at least one of the beam channel or the column channel such that the form and the corresponding form become a permanent fixture with the reinforced concrete upon curing. Additionally, the method 2310 may include arranging the form and the corresponding form to create one of a wall, a support column, or a support beam of the building structure.
CONCLUSIONAlthough several embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the claims are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claimed subject matter.
Claims
1. A building component, comprising:
- a form that is pre-shaped and made of a lightweight cementious material, the form having a channel segment that extends along at least a part of the form, a profile of the channel segment being defined, at least in part, by a first portion that projects in a first direction and a second portion that projects in a second direction that is transverse to the first direction, and the profile of the channel segment being defined from a perspective of looking at the channel segment in line with a direction of extension of the at least one channel segment,
- wherein the form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment, the abutment being between the channel segment and the corresponding channel segment such that at least one of a beam channel or a column channel is created between the form and the corresponding form.
2. The building component according to claim 1, wherein the channel segment surrounds at least a portion of an outer perimeter of the form.
3. The building component according to claim 1, wherein a thickness of the form at the channel segment is less than a thickness of the form away from the channel segment, the thickness being defined as a distance between a front surface and a back surface opposite the front surface.
4. The building component according to claim 1, wherein a thickness of the form is substantially uniform across an entirety of the form, the thickness being defined as a distance between a front surface and a back surface opposite the front surface.
5. The building component according to claim 4, wherein the channel segment is disposed into peripheral edges of the form between the front surface and the back surface.
6. The building component according to claim 1, wherein the cross-section of the channel segment is further defined by a third portion that projects in the first direction in parallel with the first portion.
7. The building component according to claim 1, wherein the channel segment is a first channel segment, and
- wherein the form further includes a second channel segment that extends in a direction orthogonal to a direction of extension of the first channel segment.
8. The building component according to claim 1, further comprising a structural reinforcement member engaged with the form.
9. The building component according to claim 8, wherein the structural reinforcement member includes one or more of: rebar, wire mesh, carbon fiber, or one or more dowels.
10. The building component according to claim 8, wherein the structural reinforcement member is embedded, at least in part, within the form.
11. A building component, comprising:
- a form that is pre-shaped, the form including a channel segment, defined, at least in part, by a base region and a wall that extends from the base region,
- wherein the form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment, the abutment being between the channel segment and the corresponding channel segment, and
- wherein: when respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel is created between the form and the corresponding form, and when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel is created between the form and the corresponding form, and
- wherein the form is made of a lightweight cementious material having a composition that provides a chemical and/or physical property such that, upon pouring and setting of a reinforced concrete mix into the beam channel or the column channel, the form bonds irreversibly to the reinforced concrete mix.
12. The building component according to claim 11, wherein the wall of the channel segment is a first wall, the first wall extending from a first side of the base region, and
- wherein the channel segment is further defined by a second wall that extends from a second side of the base region, the second side being opposite the first side.
13. The building component according to claim 11, wherein the form is a substantially planar panel, and the channel segment extends along at least a portion of a perimeter of the form.
14. The building component according to claim 11, wherein the form has a first side that is convex and a second side that is concave, and the channel segment extends along the concave second side.
15. (canceled)
16. The building component according to claim 11, wherein the form includes a chase to accommodate wiring in the building structure.
17. A method of constructing a building structure, the method comprising:
- disposing a form in a position for constructing a portion of the building structure, the form being pre-shaped and made of a lightweight cementious material, and the form including a channel segment, defined, at least in part, by a base region and a wall that extends from the base region;
- abutting a corresponding form having a corresponding channel segment against the form such that: the channel segment and the corresponding channel segment are aligned, and at least one of a beam channel or a column channel is created between the form and the corresponding form; and
- pouring a reinforced concrete mix into the at least one of the beam channel or the column channel such that the form and the corresponding form are a permanent fixture with the reinforced concrete.
18. The method according to claim 17, further comprising aligning a structural reinforcement member with at least one of the form or the corresponding form.
19. The method according to claim 17, further comprising aligning a structural reinforcement member within the at least one of the beam channel or the column channel.
20. The method according to claim 17, further comprising arranging the form and the corresponding form to create one of a wall, a support column, or a support beam of the building structure.
Type: Application
Filed: Apr 24, 2018
Publication Date: Oct 24, 2019
Inventor: Lars Benson (Hayden, ID)
Application Number: 15/961,718