SYSTEM, METHOD AND APPARATUS FOR INTEGRATED PORTABLE BUILDING FOUNDATION PLATFORM WITH MODULAR COMPONENTS

Abstract

A shelter, comprising: a foundation system configured to be filled in-place at a construction site with concrete; and a structure mounted to the foundation system, the structure walls and a roof comprising rigid foam insulation plastered with continuous filament winding (CFW), wherein the foundation, walls and roof comprise seamless transitions there between. A method of fabricating a shelter, comprising of a ‘rail system’ for pressing and gluing together foam walls, floor, ceiling, roof and foundation into a full structure. A foundation for a shelter, comprising: a portable tray configured to support the shelter, the portable tray comprising an interior configured to be filled or injected with a mass, and anchor elements configured to be anchored to an underlying formation. A modular tiling system that can be integrated into the foundation, comprising of movable functional components comprising a toilet, sink, speaker, lights, furniture, electronic equipment, cooking surface, lock box, trash bin and HVAC.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Prov. Pat. App. No. 62/909,404, filed Oct. 2, 2019, and U.S. Prov. Pat. App. No. 62/795,860, filed Jan. 23, 2019, each of which is incorporated herein by reference in its entirety.

BACKGROUND

Globally, the construction industry faces an escalating multitude of economic, labor, production and material challenges in the light residential and commercial construction markets. No country or region of the world is immune from these challenges.

Due to a rapidly growing list of forces wreaking havoc in the light construction field there is an immense market searching for improved economics, resilience and performance in the light construction industry.

• • Median-priced homes in 344 out of the 440 counties with a population of 500,000 or more were unaffordable last quarter by historical standards.
  • Housing affordability hit its worst level in nearly a decade during the first quarter of 2018.
  • In 2018, housing affordability (based on monthly mortgage payments) weakened at the fastest pace in a quarter century, according to researchers at Arch Mortgage Insurance.
  • Rising interest rates are keeping more potential buyers out of the market.
  • Production of housing is not keeping pace with demand.
  • During the 40 year period from 1968 to 2008, there was only one year in which fewer new housing units were built than in 2017, despite rising demand in a growing economy.
  • 370,000 fewer units were built in 2017 than were needed to satisfy demand.
  • Rising labor shortages plague the construction industry.
  • Changing climatic conditions are causing more damage and destruction, such as by wildfires, tornados, earthquakes and hurricanes.
  • The construction industry as a whole is generally complacent with research and development of advanced and improved building technology.
  • R&D funding for construction technology (ConTech) has historically been lacking. Out of 282 Billion dollars spent in 2009 on R&D in the United States, less than 386 million was allocated for R&D in construction.

In addition, the lack of comfortable, dignified, rapid deployment and scalable transitional shelter is a problem without a solution. Hurricane Katrina destroyed 134,000 housing units. A recent study stated that 43 million homes at the “wild land-urban interface” are vulnerable to wildfires. Lodging for mega-festivals such as Burning Man, SXSW and Coachella require rapidly deployable and removable or “flash” housing stock for tens of thousands of people. The few producers of rapid deployment shelters offer solutions that are structurally questionable, uncomfortably hot or cold and/or unsanitary. There currently exists no solution for mass scalable, rapidly deployable, temporary shelter that provides the safety, comfort and dignity of a normal home. Other solutions continue to be of interest.

SUMMARY

By improving and combining existing, underutilized materials and technologies, novel and unique methodologies were created to fabricate light structural shells. The following ideas, concepts, manufacturing and transport techniques address the affordable housing crisis, disaster susceptibility, labor shortages, high operating and maintenance costs, and ecological and sustainability shortcomings.

Examples of this building technology can provide a flexible range of offsite or onsite built prefabricated structural shells that can offer the following benefits:

• • Approximately 35% to 50% cost reduction for the structural shell compared to comparably finished conventionally constructed structures.
  • Finished appearance of a high quality site built home.
  • Superior disaster resistance to fire, wind, flooding, seismic events and added personal safety and security benefits.
  • More environmentally friendly and sustainable both during construction and over the expected life span of the structure.
  • Lower lifetime energy, operating and maintenance costs.
  • Longer useful service life span.

Embodiments of design concepts, product development, testing and prototypes for advanced hybrid shell structures are disclosed, including innovative concepts, designs, and guidance in the field of structural innovation.

The foregoing and other objects and advantages of these embodiments will be apparent to those of ordinary skill in the art in view of the following detailed description, taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of example embodiments, reference will now be made to the accompanying drawings in which:

FIG. 1 is a schematic image of an embodiment of a template for a building structure.

FIG. 2 is a schematic image of an embodiment of templates for a building structure.

FIG. 3 is an alternate schematic image of an embodiment of a template for a building structure.

FIGS. 4A-B are schematic images of embodiments of a building structure.

FIGS. 5A-C are schematic images of embodiments of fabricating a building structure.

FIGS. 6A-C are schematic images of alternate embodiments of a building structure.

FIGS. 7A-C are schematic images of other embodiments of a building structure.

FIGS. 8A-B are schematic images of embodiments of a building structure.

FIG. 9 is a schematic image of an alternate embodiment of a building structure.

FIGS. 10A-F are schematic images of embodiments of a building structure.

FIGS. 11A-E are schematic images of alternate embodiments of a building structure.

FIGS. 12A-Y are schematic images of embodiments of a building structure.

FIGS. 13A-J are schematic images of alternate embodiments of a building structure.

FIG. 14 is a schematic image of another embodiment of a building structure.

FIG. 15 is a schematic image of an alternate embodiment of a building structure.

FIG. 16 is a schematic image of an embodiment of a building structure.

FIGS. 17A-E are schematic images of an embodiment of a building structure.

FIGS. 18A-B are schematic images of another embodiment of a building structure.

FIGS. 19A-B are schematic images of an embodiment of a building structure.

FIG. 20 is a schematic image of an alternate embodiment of a building structure.

FIGS. 21A-B are schematic images of an embodiment of a portable building structure on a vehicle.

FIG. 22 is a schematic image of an embodiment of a building structure.

FIG. 23 is a schematic image of another embodiment of a building structure.

FIG. 24 is a schematic image of an embodiment of a building structure.

FIGS. 25A-E are schematic images of another embodiment of a building structure.

FIGS. 26A-B are schematic images of an embodiment of a building structure.

FIGS. 27A-B are schematic images of another embodiment of a portable building structure and vehicle for same.

DETAILED DESCRIPTION

Various terms are used to refer to particular system components. Different companies may refer to a component by different names—this document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection or through an indirect connection via other devices and connections.

The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.

FIGS. 1-27 depict embodiments of a system, method and apparatus for a building. For example, embodiments of a prefabricated, monocoque/thin shell building system can combine the economy and superior strength characteristics of a fiber and textile reinforced architectural monocoque composite panel, with the engineering, architectural freedom and material economies of thin shell roof structures. Versions of these hybrid systems can significantly reduce the multitude of disparate materials needed for most conventional construction techniques. Rather, examples can rely on two readily available primary components for fabrication: a rigid, insulating foam core and textile reinforced high strength plasters for both interior and exterior surfaces.

Versions of the system can take full advantage of the time and cost saving efficiencies offered by offsite prefabrication. Factory fabrication processes can convert a sporadic, problematic and lengthy onsite construction process into a precisely controlled manufacturing assembly line production. Embodiments of flexible assembly line manufacturing templates can create both permanent and portable, easily relocatable building shells.

Examples of the building shells can use commonly available rigid foam insulation, which can serve a multitude of functions in these structures, coupled with new processes not previously utilized in building construction. Some versions can include continuous filament winding (CFW). CFW can imbue these structures with immense structural strength, rigidity, moisture and vapor resistance and an almost seamless, fireproof exterior surface. Embodiments of a “tray” foundation system can enable the lightweight building shell to be transported to the final destination, placed in position and filled with concrete to provide a permanent, insulated, slab-on-grade foundation. Versions of the fiber and textile reinforcing methods can be combined with novel approaches to protect our structures from wind and seismic damage.

Examples can include economically priced, disaster resistant (e.g., flood, fire, tornado, hurricane, earthquake), environmentally friendly, architecturally appealing, superinsulated and thermally efficient structures. Embodiments can include 100% finished building shell assemblies, or individual components of building shells that can be easily and shipped and assembled onsite.

The manner in which techniques are combined and improved, coupled with the unique manufacturing and construction methods developed, offer a new and improved building approach that can significantly reduce the cost of shelter while simultaneously increasing the efficiency, safety and performance of the structures.

Economics and Cost Savings

Examples of the completed, prefabricated shells can provide a 35% to 50% cost reduction when compared to comparably finished, conventionally constructed, site-built building shells. These designs also can provide the additional benefit of a vastly accelerated delivery schedule.

Shell Sizes

Embodiments of the factory prefabrication system can quickly adapt to produce structures that range in size from small ancillary “back yard” buildings up to small office and retail buildings and moderate sized residential structures of a single family or multifamily nature. The manufacturing templates can allow quickly produced buildings in, for example, five standard widths from about 12′ to about 28′, and lengths from about 12′ to about 48′ in approximately 4′ increments. This system can produce about 50 standard shell floor sizes ranging from about 144 sf up to about 1,344 sf in area. Versions of the templates can provide the flexibility to produce each floor size with, for example, three different plate heights, effectively yielding about 150 different product sizes from one easily adapted manufacturing template.

For example, Table 1 depicts available module square footages with a width of 28′ and a length of 48′.

	TABLE 1
	LENGTH
	12	16	20	24	28
		12	144	192	240	288	336
		16	192	256	320	384	448
	W	20	240	320	400	480	560
	I	24	288	384	480	576	672
	D	28	336	448	560	672	784
	T	32	384	512	640	768	896
	H	36	432	576	720	864	1008
		40	480	640	800	960	1120
		44	528	704	880	1056	1232
		48	576	768	960	1152	1344

Examples of Markets and Uses

Examples of markets and potential uses of these structures include the following applications.

	Market Rate	Permanent Disaster	Affordable
	Housing	Relief Housing	Housing
	Vacation Homes	Military/DOD	Homeless
	and Cabins	Housing Units	Housing
	Tiny Homes	Accessory Dwelling	Portable
		Units ADU's	Classrooms
	Portable Sales	Conditioned	Back yard
	Centers	Storage Units	Offices/Hobby
	Man/Work Camp	Dormitory Units	Improved
	Housing		Mobile Homes
	Small Single	Backyard Rental	Small Office
	Occupant Homes	Units	or Retail
	Prefab pods for industrial loft conversions
	Lightweight Rooftop Penthouse Units crane set onto existing
	buildings
	Prefab pods with offices, breakroom and restrooms for
	warehouse and industrial spaces

Individual units can be grouped or combined to create, for example:

	Climate Controlled	School/	Office/Retail
	Storage Complexes	Classroom Pods	Strip Centers
	Office Compounds for Speculative sales or rentals
	Cottage Compounds for Long or Short Term Residential
	Rentals
	Duplex, Quadraplex, Apartments - Multi-family Housing

Thin Shell Roof Structure

Thin shells rely on arch or shell geometry using a minimal amount of material to cover a large surface area or span long distances. Thin shells are relatively light for their high imparted strength. The lack of popularity of thin shells in the North American market was primarily due to the high expenses incurred for form labor and form materials necessary to create these flowing structures. Traditional shell forming methods require many hours of skilled labor expense, rigid quality and dimensional tolerances, massive amounts of materials for shoring and forming that are generally “single use applications” and exacting concrete placement and finishing procedures.

In contrast, the embodiments disclosed can include an inherent precision in the thin shell roof forms. These exacting shell shapes can be cut from inexpensive, lightweight rigid foams. The precut foam forms can be assembled using manufacturing templates and processes disclosed herein. In addition, applications of various high strength textile reinforcing materials and thin coats of high strength Portland cement, magnesium-based or other high strength plasters can be employed.

Monocoque Shell/Architectural Composite Panel Blend

Conventional wood frame construction uses non-load bearing external building skins with internal structural load bearing frameworks. In contrast, the monocoque or “single shell” technique is a fabrication type that supports structural loads using an object's external skin. For example, a surface can be formed wherein inner and outer layers act together as a unified, structural whole. The inner and outer surfaces can be separately constructed and interconnected through a spaceframe, such as a rigid foam core.

Composite panels can include a composite material or composite comprising a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure, which differentiates composites from mixtures and solid solutions. The composite can be preferred for reasons such as providing stronger, lighter or less expensive materials compared to traditional materials.

In some embodiments, foam core can be a superinsulator, and can function as the “web” of a “beam,” and the two shell surfaces can function as the “beam flanges”. The interior and exterior composite panel structural plaster layers can function as the flanges and the fibers, plaster, and textile reinforcing layers can form the strong composite panel surfaces. These architectural composite monocoque shells can eliminate the multitude of plates, sill sealers, caulks, studs, sheathing, vapor barriers, insulation layers, drywall, nails, screws, adhesives, masonry or siding veneers, etc., of conventional wood or stick framing and rely on their structural skins to support themselves.

Continuous Filament Winding

The majority of damage and destruction caused by wind, seismic events and flooding can come from inadequate or weak connections at the transitions at the foundation-to-wall and/or the wall-to-roof of a structure. Massive structure losses due to wildfires are caused by combustible exterior wall and roof surfaces coupled with sparks and embers entering vented attic space. The present examples can include fabrication methods that can secure the foundation, walls and roof together to provide a virtually seamless and ultra-high strength transition from one surface plane to the next.

In some embodiments, the manufacturing concept can use a modified continuous filament winding method (CFW). Continuous filament winding can employ various strands or high strength rovings (e.g., a long and narrow bundle of fibers) such as glass fiber, carbon fiber, polypropylene, basalt, etc. These materials can be drawn through a resin bath and placed on a rotating mandrel to create high strength shapes.

As opposed to conventional CFW production methods, the examples disclosed herein can use a system where the building shell does not rotate. Instead, self-tensioning creels of high strength material, such as roving, can travel on a continuous looped track that encircles the exterior shell (e.g., rigid foam core) of the structure as it progresses through a winding station. The roving fibers can be wound onto the building shell while under slight tension which, in turn, can place the foam shell into slight compression. The textile reinforcing rovings can be deposited and tensioned on top of horizontal “stand offs” or “hold offs”. Examples of the hold offs can be fabricated from basalt rods, fiber reinforced mix or other products. The hold offs can keep the rovings suspended slightly above the foam surface, effectively keeping the textile reinforcing centered within the high strength plaster matrix. In some embodiments of the system, the filaments may or may not be drawn through a resin, Portland cement based bath or other mixture. Examples of the filaments can be applied dry prior to receiving the spray applied, fiber reinforced, high strength structural plaster coating at a station further along the assembly line.

Examples of the Manufacturing Process

• 1. One version can start by placing the wall assembly tubes and floor assembly guide rails in the appropriate positions in the beginning rolling press wall and fixed end wall template for the width and wall plate height positions for the desired building profile.
• 2. Next, roof panel assembly tubes can be installed into both the rolling press wall and fixed end wall template depending on the desired ceiling height.
• 3. The fabrication can be built with approximately 10′ to about 12′ of assembly tubes protruding through the fixed end wall template and extend through the first “rolling” end wall template by about 6′ to about 8′. The assembly guide tubes can be left well shy of the sliding “rolling far end wall” or second rolling wall template.
• 4. The first set of precut foam “tray” foundation elements can be positioned against the first rolling end wall template providing the first 4′ deep, full width foundation “tray” band element.
• 5. The first precut 4′ wide vertical side wall elements can be slid into position and held approximately 48″ away from their final location on the “tray”.
• 6. The first precut 4′ wide roofing assembly can be placed into position flush with and directly on top of the first wall sections. “Tray” foundation to wall and wall to roof joints can be completely covered with the appropriate foam to foam adhesive and slid into final position where all “tray” wall and roof planes can be aligned and flush. At this stage the first bent or 4′ wide module of floor “tray,” walls and roof structure can be completely assembled and bonded.
• 7. In some embodiments, a 1″ band of basalt or comparable strapping material can be centered in the first 4′ section and slightly tensioned to hold the first 4′ wide “tray”, wall and roof panels in position until the adhesive sets up. The band can be lightly adhered to the walls and roof panels but can be left loose under the “tray” foundation foam until it is lightly tensioned and banding clamps are applied.
• 8. After each succeeding 4′ “tray”, wall, and roof section is assembled and bonded, advance enough of the guide and assembly tubes through the fixed and first “rolling” end wall template to receive the next 4′ section leaving a comfortable overhang of tube length past the assembled section.
• 9. Steps 4 through 8 can be repeated for each 4′ long section of full building length leaving about 1′ to 2′ of space between each preassembled, bonded and strapped 4′ section.
• 10. Once all 4′ long “tray”, wall and roof sections have been assembled, bonded, strapped and cured, continuous foam can be applied to form adhesive bonds on the inside surface of each 4′ long “tray”, wall and roof section. The second or last rolling end wall assembly can be advanced back towards the fixed first rolling end wall and fixed template assemblies enough to run the guide tubes into the second “far end” end wall section. An even clamping pressure can be applied by advancing the second end wall template to compress all 4′ sections into the final desired length. This assembly can be held in position until all adhesive bonds have fully cured.
• 11. The interior of the assembly precut end wall foam sections can be assembled and placed on top of beads of foam to foam adhesive on the first Tray section, up against the inside surface of each exterior wall and snugly fit and glued to the underside surface of the roof/ceiling sections and are pressed and temporarily secured snugly against the inside surface of the “first rolling” and “rolling far end” end wall template.
• 12. After a sufficient adhesive curing period, the second “far end” end wall template and first and second templates can be loosened and withdrawn slightly. Unneeded assembly and guide tubes can be withdrawn from the shell assembly. Depending on the width and length of the structure, 2 to 8 of the “Tray” assembly rails and wall and roof guide tubes can be left in position to serve as temporary transportation rails and braces. The required rails can then be connected to the assembly and transport dollies. The first and second rolling end wall templates can then be removed and “leap frogged” around the shell assembly back into starting position. Using the assembly rails and transport dollies, the Shell can then be advanced to the next station position.
• 13. At the second station, the strapping bands can be cut loose at their midpoint under the “Tray” foundation. They loose ends of the bands can be coiled and plastic bagged for protection and later use.
• 14. Horizontal “hold offs,” such as rods of basalt, with a bond such as liquid applied fibered cement mix or other appropriate materials, can then be applied to the bottom surface of the “Tray.” The exterior wall surfaces and the roof surface can be in a spacing ranging from about 12″ to about 24″ on center. These “hold off” rods can position this rebar or mesh-like material to reinforce the center of the applied matrix. The rods can serve to “hold off” or center the continuously wound filament within the middle of the fiber reinforced structural plaster layer, rather than allowing the filament windings to lay directly on the rigid foam surface where their intended strength can be imparted to the composite panel matrix.
• 15. Next, all precut interior rigid foam wall, soffits and bulkheads can be installed using foam to foam adhesives.
• 16. Window and doorjamb, header and sill elements can be formed from a proprietary fiber reinforced mix, and can be installed using compatible adhesives. Fiber reinforced blocking materials can be either poured and troweled or bonded into place depending on the location and desired function.
• 17. The entire assembly can then be advanced to the continuous filament winding station where the assembly advances through the winding process until completed.
• 18. The assembly can proceed from the winding station to the next station where winding filaments can be cut and secured at window and door edges prior to plastering.
• 19. Windows, doors, plumbing vents, conduit penetrations, plug, switch and lighting boxes can be installed and sealed prior to plastering. All finished or exposed elements can be masked and taped off prior to plastering.
• 20. After all surface preparations are complete, a final cross check and quality control review can be performed. Spray applications of high strength reinforced plasters can be applied to both exterior and interior surfaces. If the building is slated to be a portable and relocatable building, the interior floor surface of the “Tray” foundation system can receive a ⅜″ to ⅝″ layer of fiber reinforced plaster.
• 21. After an adequate curing period, the assembly can progress to the finishing stage where all exterior decorative finishes are applied. At this station the final roofing surface can be applied.
• 22. After the last step of applying exterior surface finishes, the lightweight basalt reinforcing can be placed into the “Tray” and the Shell can be readied for transport.
• 23. Shell units intended to serve as relocatable portable building structures and improved “mobile” or modular buildings can proceed through additional manufacturing stations and receive most if not all of the final fit and finish out, leaving anchoring and utility connections to be made after delivery and placement at the final destination.
• 24. Most if not all manufacturing procedures and production stages to the stages can be completed in the plant. Some shells would need only transport, placement, anchoring, utility connections and concrete placement and finish of the final permanent foundation after delivery to the final destination.

“Tray” Slab on Grade, Insulated, Concrete Foundation

Embodiments of the prefabricated wall and roof structures can be assembled on the rigid foam tray in a plant environment. After job site placement, the tray can provide a permanent formwork for a super insulated slab-on-grade foundation. Insulated slab-on-grade foundations can provide advantages.

During the final stages of the prefabrication process, a lightweight yet ultra-high strength rebar grid and/or mesh (e.g., basalt) can be placed into the rigid foam tray. The completed shell can be transported to the final destination with the described fabrication and transport dollies. The unit can be placed on a level pad, the transport dollies can be removed, and then connect water, sewer and other services. After final alignment, quality checks and appropriate building code inspections are complete, the tray can be filled with concrete or concrete-like material on-site to provide a superinsulated slab foundation. This capability can remove a possible stigma or perception of low quality due to a portable or raised foundation (e.g. ‘trailer homes’) and satisfies most municipal and city code and subdivision deed restriction requirements prohibiting modular units or requiring all new construction to be installed on permanent foundations.

Depending on local wind loading, soil bearing capacities and seismic design loads, portions of the foam tray may be cut out or removed to allow the poured concrete to directly contact the ground. Small belled concrete pads can be cut or slab connections provided to reinforced concrete piers or pilings. The concrete slab can be finished with flooring including carpet, wood, tile, integral concrete dye or acid stain, water-based sealers, etc. The system can be adapted to integrate with elevated piers, helical piers and other foundation types.

Plant fabrication templates can permit the formation of both permanently installed and portable building shells. The tray shells of portable shell buildings can employ the same fiber reinforced structural coating used on the walls and roofs, The floors can be covered with floor covering. The construction methods and light weight of the product allows these buildings to be transported and relocated with ease.

Superior Anchoring and Tensioning for Wind and Seismic Loading

Building structures can be securely anchored yet remain slightly flexible in order to resist wind loading, roof loads, seismic events, hurricanes and floods. The disclosed hybrid system can use high strength textile reinforcement that, when applied with very slight tension, places the structural shell under a slight compressive load. Through the use of continuous filament winding and a variety of proprietary anchoring techniques the structures can be securely anchored to the earth.

Embodiments of the tie down and anchoring procedures provide a superior anchoring technique that far surpasses any wind, tornado, or hurricane tie down method used in conventional construction. The tie down systems can be economical and translate and crossover for application to almost any construction technique. In addition, the system can be used to retrofit existing structures.

As described and illustrated, a high strength strapping material can be applied around the midpoint of each 4′ section as a temporary strapping aid in bracing, aligning and bonding the shells together. The strapping can be cut loose at the midpoint under the Tray after filament winding. The straps can be coiled, wrapped and protected prior to plaster. These high tensile strength straps can be used during shipping as additional tie downs or attachment points. After delivery, the straps can be tied back directly into the “Tray” rebar reinforcing for a continuous roof/wall/slab connection, or they can be tied or attached to any number of optional ground anchors.

GeoTie Soil Anchors

Geogrids and Geocells are two and three-dimensional mat materials designed to hold and stabilize soils, stone, etc. from shifting or rutting. They can be used in a modified manner by placing them beneath the location of a future building. The mat can be covered with compacted stone or base materials. The outside perimeter edges of the mat can be brought to the surface in a rough outline of the perimeter of our building where the strapping material can be banded and tensioned to the mat as an anchor at each location around the building shell when the building is delivered and set up. The continuous tie between the strapping and the mat can provide an immense resistive holding power against wind loads or seismic forces.

Portable Building Anchoring

Assembly and Service Channels

Prior to assembling the precut foam blanks into foundation trays, wall segments and roof panels, channels can be hot wire cut to serve double duty as alignment guides during construction assembly, and function as electrical and low voltage AV conduits, sleeves for supply and return lines for cold and hot water piping, coolant and condensate lines for HVAC equipment. Some channels can be used to carry ductwork for high velocity systems. Alternatively, they can be HVAC plenums and ducts using void spaces in the rigid foam panels that are coated with a fireproof duct coating and serve as permanent ductwork. Larger channels cut into the tray foundation forms can function both as sleeves for assembly and transport rails, and also can be used as under slab utility chases and/or reinforced concrete beams, depending on structural requirements. Unused channels and sleeves can remain open in the structure to accommodate additional wiring for other purposes, such as technology upgrades.

To address disaster and flood resilience and recovery, these conduit runs and systems can be installed with positive drainage capability. Adaptor devices can be used to connect high pressure air to one or more standard electric junction boxes or locations within the runs. Drain valves can be opened or closed to isolate or pinpoint pressurized air delivery. The air can be supplied under high pressure, such that debris and liquids can be forced out at designated drain locations within these conduit runs. Additional cleaning and disinfection materials can then be introduced and flushed through the lines to remove moisture and eliminate mold and mildew issues.

The Insulating Foam Core

Embodiments can include a lightweight foam core as a building component in the system. This component can provide multiple services in the designs. The foam core can serve as the monocoque “space frame” or beam web connection between the inner and outer wall surfaces. The structures can use the same lightweight core material for the tray foundation, exterior and interior walls and the roof and ceiling structure. This inexpensive, insulating core can serve as a permanent, “stay-in-place” formwork necessary to form the thin shell arched roof profiles, instead of the labor intensive and form and shoring material heavy processes that standard thin shell techniques use.

Examples of the base shell walls can use about 12″ of 1.5 lb EPS foam to yield a core value of about R-54.6 at 40 degrees, and about R-50.0 at 75 degrees Fahrenheit. Versions of the roof structures can include a core thickness of about 12″ to about 24″ to yield a core value of about R-109.20 at 40 degrees, and about R-100.80 at 75 degrees Fahrenheit. EPS or other lightweight rigid insulation can be used, such as 1.5 lb/cf density EPS foam. These materials can include one or more additives, such as a graphite additive that increases the R Value and flexural strength of EPS foam.

Other versions of the system can use environmentally friendly and sustainable insulation products, cellular glass products, ecologically friendly wood based foams or aggregates, plant based insulations, polymer/clay aerogels, mycelium and cellulose based insulations, etc.

Recycled EPS or “regrind” foam from the EPS waste stream can be used in the prefabricated building units, and can be converted to a lower cost feed stock for new shell structures. For example, wall and roof structure designs can include alkaline resistant, fiber reinforced, high strength Portland cement based plasters applied over high tensile strength fabric reinforcing including basalt, glass and carbon fiber roving or basalt and fiberglass mesh. The rigid insulation foam core materials can be shaped with hot wire cutting machines, saws, rasps and simple hand tools. Hot wire machines are available in hand-held, table top and large multi-wire CNC controlled units. The foam core materials also can be bent or tensioned in curved shapes to provide the calculated arch or “thin shell” roof and ceiling shape. Foam panel materials can be joined and assembled using adhesives.

Foundation requirements for these lightweight shell structures can be vastly reduced due to the extremely lightweight nature of the building shell. The logistics of transporting lightweight prefabricated shells are simplified as well. The concrete beam depth can be significantly reduced to allow a labor reduction and reduced concrete and reinforcing cost.

Composite Panel Surface Coatings and Textile Reinforcing

Embodiments can include high strength plaster coatings and textile reinforcing applied to the inner and outer surfaces of the insulating foam core to form a high strength composite panel. Most structural insulated panels (SIP) use oriented strand board (OSB) adhered to a foam core to provide the outer skin. In contrast, embodiments can use a high strength structural plaster coating as the skin on both sides of the walls, roof and ceilings. The plaster coating can be fiber reinforced or may be non-fibered and applied to a mesh reinforcing layer. Alternatively, textile reinforcing techniques can be employed.

The prefabricated buildings are lightweight for ease in assembly and shipping. Basalt rebar, fibers and mesh can be used for their light weight, high strength to weight ratio compared to steel, environmental advantages, sustainability properties and non-corrosive composition. Basalt rebar can be 89% lighter than steel rebar and yield the same strength. Depending on the size and shape of the structure and the spans and loads involved, lightweight basalt rebar can be used to provide additional support to the shell walls and roof structures. Basalt rebar can offer an added benefit of inherent spring properties that can provide a significant improvement over conventional rebar. Basalt products have an additional advantage over carbon fiber and other advanced reinforcing products due to much lower cost and extreme environmental benefits.

Interior and exterior walls and ceilings can be painted with latex and elastomeric paints or plaster finishes. They can be finished with gypsum or earth based plasters, stone, brick or other façade. The plaster exterior can be a seamless, fireproof finish.

In some versions, no wood, sheetrock or drywall products are required. Examples of the shell building structure materials and surface coatings do not support mildew or mold growth. In the event of flooding, all electrical, audio/video and low voltage routing is contained in conduit with ports that can be purged with compressed air to remove water and moisture from the interior electric and communication conduits. Additional heated lower velocity air can be applied to all conduits to further dry and remove residual moisture.

Embodiments of the system offers benefits including an easily procured, smaller and more localized supply stream. Reduced transportation costs are provided for both for the raw materials and for final delivery. Compared to conventional on-site and prefabricated wood frame based construction systems, there is a substantial reduction in the amount of waste building products generated using this system. The majority of waste products generated during manufacturing can be collected, recycled and repurposed into components that can be used in the manufacturing processes. For example, rigid foam scraps generated from cutting and routing operations can be converted into EPS regrind. Structural plaster overspray can be collected and re-ground to a uniform aggregate size. Scraps from the textile reinforcing and fibers can be chopped into smaller particle sizes. These materials can be combined in a mix design for window and door bucks and blocking channels. The assembly procedures can eliminate most specialty plant requirements. Other than the initial manufacturing templates, the structures are formed by very few specialized tools and equipment.

Roofing Options

In some versions, securely attachable, nailable decking products can be joined to the shell structures if metal roofing, composition shingle or other roofing options are preferred. Other versions can include application of a liquid roofing product over the structural plaster. Rated acrylic elastomers applied with a sprayer and paint rollers, such as silicone roofing products can be used.

Examples can include fiber reinforced, acrylic modified Portland cement based lightweight aggregate mix designs that, once cured, exhibit material properties that bind to most rigid foams with exceptional strength. As described herein, recycled EPS foam waste, plaster overspray and fiber and textile reinforcing waste generated by the process can be used in this mix design. Additional useful properties offered by the mix are it is nailable and holds coarse threaded screws well and cuts and shapes. Cast and milled pieces of this product can be used as window and door opening headers, jambs and sills. In addition, channels can be cut in the foam cores that can be filled with this wet mix, or cured pieces can be adhered inside the channels to function as nail and screw holding blocking for cabinets, toilet and bath accessories, roof decking products, etc.

The building systems can include a variety of building shapes such as modern design, Southwestern, Mediterranean, Spanish Colonial, Pueblo, and American ranch, etc. The following drawings illustrate some of the basic architectural building shapes, roof profiles, and ceiling treatments that can be provided.

Manufacturing Facilities

Embodiments of a manufacturing process and operation to produce shells can be a permanent facility or a temporary facility within the development it is serving. Such operations can significantly reduce time, logistics and transportation costs. The temporary manufacturing facility could be constructed on a street paving section within the development. After the development is built out, the facility can be deconstructed, relocated to a new delivery location, and powered back up within a short time frame. The permanent site built manufacturing facility could be converted into an alternate use after project build out such as an amenity center, gymnasium, activity center, educational institution or civic structure after it has served its original purpose.

Tooling and Equipment Costs

After preparing the facility and constructing the four end wall panel jigs and assembly dies, the system design can accommodate fabrication of major system components with automated equipment, or manually operated tools, either of which enable a significant reduction in tool and equipment needs compared to conventional methods.

Transport Shipping and Handling

During manufacturing and assembly, the lightweight foam shell assemblies and system components can be handled and placed by manual or automated equipment. The lightweight components and finishes reduce foundation requirements, expense and offer additional benefits in active seismic zones.

In one example, a width of up to 28′ for new modular or prefabricated buildings is permitted to be transported over-the-road by some states. State laws can allow an additional 2′ of eave or soffit overhang on each side of the 28′ body width, effectively yielding a total width at 32′.

House and mobile home movers typically can move structures with lengths up to about 60′. Versions of the present system can be adaptable to produce units of any desired length, including longer than 60′. One example includes a length of 48′ to facilitate transportation and placement in tight urban environments. Individual shells or assemblies can be combined to create much larger office, retail, or other type building structures.

Embodiments can include one or more of the following attributes.

• 1. The completed building shell cost can be significantly less than any conventional construction method and can provide additional savings long after the initial purchase.
• 2. The finished product can have a “mainstream” exterior and interior appearance that is recognizable and readily acceptable in the US and international marketplace.
  • a. Observation of previous marketplace failures in alternative building systems such as monolithic domes, geodesic domes, Quonset homes, hexagonal homes, etc. shows that market acceptance of alternative building system designs can be limited if the system has an exterior appearance that does not appear “normal” or mainstream in either its composition, shape, color, material or finish.
  • b. The system can be readily adaptable to varying locations. The designs can be architecturally flexible or adaptable to regional markets. Examples, such as southwestern, modern, contemporary and other architectural styles can be attained.
  • c. The system can include a variety of standard sizes and individual modules or components that can be combined to form different layouts and appearances.
• 3. The immediate and ongoing operating costs for energy usage and long term maintenance can achieve savings over and above what is currently possible with traditional construction methods. Embodiments can provide superior thermal performance. For example, continuous insulation could eliminate thermal bridging.
• 4. The structures can be environmentally friendly and sustainable both during construction and for the long term health of the occupants. The structures can be fire, wind, flood, and earthquake resistant. Bullet and impact resistance can be provided. The structures can be relatively impervious to environmental damage whether natural or man-made.
  • a. Embodiments can include a virtually seamless exterior and interior wall and roof shell. The exterior finished surfaces can be fireproof and resistant to mold growth. A reduction in seams, laps, joints, material intersections or overlaps reduces the quantity of disparate construction materials and likelihood of air and moisture intrusion.
  • b. Versions can include a seamless, “hard shell” exterior to vastly reduce the potential for fire and water intrusion and wind separation or damage. All exterior and interior wall, roof and ceiling surfaces can be non-combustible.
  • c. The structure can be mold and rot resistant. Foundation, walls and roof structures do not absorb water or promote mold growth.

Standardization/Prefabrication/Time Savings/Manufacturing Flexibility

Cost efficiencies can be obtained by using standard or repetitive designs. Examples can include:

1. Prefabricated Components. Examples can include a flexible system that can be manufactured under a wide variety of circumstances. Major components can be fabricated and erected wholly onsite, or they could be manufactured and partially assembled offsite and transported to the jobsite and erected into a finished product.
2. Panelization. Foundation, wall and roof system components can be capable of panelization to derive the cost savings and handling benefits.
3. Completed Prefabricated Shell. A completed prefabricated structural shell can be transported, set in place and permanently anchored. The prefabricated structures can be designed to be finished as completed permanent structures when set at their final location. Alternatively, the fabrication techniques can be modified to produce relocatable portable buildings.

Embodiments of the structural plasters can include one or more of: Portland cement, alkali resistant fibers, cement performance additives including, for example, strengtheners, plasticizers, water reducing agents, retarders, silica fume, pozzolans, lightweight rebar and others.

In some versions, additional materials for the structural assembly processes can include one or more of foam-to-foam adhesives, rovings used in a continuous filament winding process, fabric mesh used for reinforcing at corners and stress points

Examples of interior and exterior surface finishes can use one or more of latex based paints or gypsum and earth based plasters. Other examples can include roofing solutions such as acrylic elastomeric and silicone based liquid roofing products.

Other embodiments can include one or more of sealing and waterproofing in sub-slab locations, wall and roof penetration and flashing areas with sheet membranes and liquid applied waterproofing materials.

Versions can include trim details, plaster expansion joints, screeds, trims at corners transitions, windows and doors, etc., such as by using readily available vinyl extrusions fabricated for the plaster and drywall industries. A variety of caulk and sealants can be utilized at windows, doors, foundation plaster screeds, etc.

Site-Built Embodiments

Other embodiments can include securing lightweight structures to a permanent concrete slab-on-grade foundation. These can be applied to the hybrid rigid foam composite panel shell structure described herein. These techniques also can be applied to wood frame structures, light gage steel frame structures, pre-engineered steel buildings, etc. Further, they can be used and applied to virtually any new construction method, and modified to be retrofitted to most existing structures. These designs can securely attach buildings and mitigate the potential damaging effects from wind, seismic and flooding events.

In some versions, installation of the design can include:

• • 1. After assembling a concrete form for a concrete pour, form or drill holes in the top foundation boards at approximately 12″ intervals, approximately 2″ down from the tops of the top foundation boards. The hole size can be sufficient to force a loop of the preferred tie material through. Engineering calculations can be performed to determine the quantity of ties and wraps required to determine appropriate spacing. The top form board can be approximately 3/16″ to about ¼″ thicker than the lower form boards to leave a shallow pocket to receive: termite mesh, tie loop and wrap ties and clips, etc.
  • 2. Secure a short loop of high tensile strength roving, basalt, carbon fiber, glass fiber, strapping, twine or roving, etc., to the rebar reinforcement of the soon-to-be-poured concrete slab. In the illustrated example, the loop is applied and tied off to the lower exterior beam reinforcing rebar.
  • 3. In each of holes drilled through the top foundation board, insert an approximately 2″ long loop through from the interior of the form to the exterior and tape it down to the exterior of the form board to keep it from snagging.
  • 4. Pour slab and cure.
  • 5. Remove the form boards and clean any residue or debris from loops.
  • 6. Install, for example, vinyl L angle stops on the slab in appropriate position as an index guide for walls.
  • 7. Apply adhesive and set wall rigid foam wall and roof sections in place and brace and secure to vinyl L angle stops with screws and foam washers.
  • 8. Apply termite mesh using appropriate cement based adhesive over the horizontal joint or junction of the concrete slab and rigid foam wall. The bottom edge of the mesh can be located above the tie loop.
  • 9. Fill the recessed area of foam and concrete with appropriate fiber reinforced plaster mix, without making the tie loops unusable.
  • 10. Apply, for example, basalt or fiber reinforced hold offs to wall and roof panels.
  • 11. Beginning on one side of the structure tie off the beginning filament wrap to the first loop of the wall section using a tie or suitable clip.
  • 12. Cross the filament wrap up the wall and over the roof to the corresponding loop on the opposite side of the structure and loop through and begin returning up and across the building.
  • 13. Using a manual, electric or air powered tensioning device exert the desired tension on the first cross building tie and secure with the appropriate banding clamp or tie method.
  • 14. Advance the strapping across the roof system and back to the next loop on the opposite side.
  • 15. Loop the strap through and apply tension and band or clamp on that side.
  • 16. Continue the process, alternating applying tension on opposite sides until the entire structure has received the first course of filament wrapping, tensioning and clamps.
  • 17. Optionally, begin applying loops to and from opposite sides of the structure at angles up to about 45 degrees to encapsulate the entire building in a high strength wrap.
  • 18. After completing the wrapping process proceed with construction processes.

Temporary Shelter

FIGS. 17-27 illustrate various examples of alternative embodiments. The examples disclosed herein can include a lightweight, transportable foundation platform that can function as a secure format for many permanent and virtually any temporary structures including, for example, tents, 3D printed homes, modular shell packages, and even conventionally constructed homes. From a structural safety perspective, the foundation base can be injected with material, such as sand, or receive precast weights during placement to ballast the living structure against wind loads. For permanent applications, the unit can be designed to receive a simple premixed concrete or grout injection, in effect providing an engineered response to most code and permitting requirements. Versions can be smart device-enabled (e.g., Siri, Alexa, etc.) and app-controlled (such as via a mobile phone). For example, the base can contain a package of technology and utility services including, e.g., hot-swappable removable and rechargeable batteries; fresh/black/grey water swappable or easily refillable tank pods; and/or in-floor heating and cooling. Embodiments of the modular tiling system can allow plug-and-play options, such as a variety of furniture and devices removably installed in the base. Other examples can include toilets, modular showers, interior walls, speakers, chairs, tables and beds, etc. Also disclosed is a new form of wall and roof structure that can be insulated or even super-insulated (R50), sound-proofed, weather-resistant, bullet-proof, can be flat-packed, etc. Embodiments can include a winch-and-wrap technology that can permit them to be easily assembled, such as by two people in minutes. Versions can require no poles, fasteners, tools, or specialized construction equipment. The base units can be connected to form a variety of larger base sizes in numerous configurations. Integral horizontal conduits can allow post-tension cabling, of multiple units for temporary or permanent installations. Additional vertical channels can allow the insertion of structural tubular members that can enable the units to be connected into multi-story complexes, or to easily respond to marshy conditions, sloped terrain or other challenging environments. Other integral conduit channels can allow the insertion and connection of fresh water, black and gray water, data fiber, power and AV lines, etc., through interconnected units. These designs can effectively form a linked grouping or pod of units serviced by central facilities. Other specialized base units may be provided as walkways or connections between grouped units to enable utilities raceways. Embodiments of the units can provide capabilities for solar installations and integral battery storage. Additional configurations can provide mounting locations for generators and fuel tank integration.

Embodiments can include one or more of the following items:

A versatile, temporary or permanent foundation platform that can function independently or in combination with additional units or proprietary products.

A foundation product that can be self-contained, or fully self-contained, including (for example) fresh/grey/black water storage, solar ready, battery-powered electricity, HVAC, and/or other comfort-inducing technology.

A foundation product that can easily connect to external power, A/V, fiber, water and sewer services, etc., through internal raceways and/or channels.

Integral cavities in the foundation that can be filled with materials such as sand, stone, precast weights or water to ballast and provide structural stability. The sand/water can then be removed so that the building is once again portable. The cavity also can be injected with cement or suitable grouts to make the structure permanent and compatible with municipal standards.

Base needs can include integrated water/wastewater system for toilet/sink/shower.

A modular tiling system can allow for placement of various implements at any place on, in or under the platform, including, but not limited to: toilets, sinks, speakers, lights, furniture, wifi/IOT, heated flooring, cooking surfaces, A/C heating etc. The modular tiles can connect into the surface of the foundation platform in a mechanical way, and can contain various combinations of connections for electrical, data, and plumbing.

A connection design for the aforementioned implements can be characterized as a Simple Foundation Interface (“SFI”) connection. Such an interface can be specific to Foundations by SIMPLE, and can allow implements to lock into place. Such designs can allow an open source interface of product creation that can be “SFI Compatible” and lock into the existing modular tiling of the foundation.

Tiles

• • Modular trash can and trash tray.
  • A lock box tile module for valuables.
  • Radiant heating/cooling tiles mounted to or embedded in the slab.
  • Drop-in batteries.
  • Drop-in fresh water and black water tanks.

Smart sensors that detect tank levels and refill times.

Integral mobile phone apps that monitor all utility and services.

Hardware such as rings can be embedded along the side of the foundation for looping the basalt cord wrap in and out. A winch can pull the basalt cord around the walls to tighten them. Pre-punched holes may be cast into the platform edges to receive tent and rigid structure tie downs or “wraps”.

A tent or other structure could be affixed to the foundation platform.

An external ‘delivery slot’ that can allow for packages or food to be delivered from an exterior of the structure.

Internal chases and conduits can provide integral connections to normal utility ‘on-grid’ hookups.

A data collection system can be included or embedded in the slab that can allow for, as examples, collection of climate, sound, movement, pressure/weight, and/or other forms of data on top of the slab.

Precise geolocation technology can be included or built into the foundation that can allow for navigation to the foundation using an application on a computer device, such as via an iOS or Android device.

Click-in on bottom corners and middle of edges for, as examples, casters, robots or foundation jacks. Disk joint connections on sides of bottom corners can connect additional foundations to expand size. Slightly curved lip to edges of foundation can prevent the influx of insects and other elemental issues.

Platform base units may be manufactured with integral brackets and fasteners designed to interconnect with casters, rollers, trailer tongues and towing apparatus, lift points for crane pick and setting points, transport rails and yokes, etc.

To reduce manufacturing costs, complexity and overall weight, an embodiment of a manufacturing technique could use additive 3D printing techniques and high strength composite materials, such as those combined with basalt, carbon fiber, Kevlar or other reinforcing materials to form lightweight, truss frame platforms that encapsulate some or all of the required structural support, base and top deck layer bearing surfaces, conduit supports and runs whether integral or to receive readily available commercial products, sleeves for supplemental supports columns, piers, lifting eyes, tent or wall and roof panel tie downs and wraps, post tension cable sleeves and attachment points, etc. These same printing techniques can be used to create the required pockets for holding tanks, equipment platforms, etc. Some non-toxic 3D printing materials may be utilized to print the complete fresh, gray and black water holding tank cells.

A second optional manufacturing technique can include CNC milling of full platforms or platform components that can interlock or “slot” together to form a completed base unit. These components can be milled or machined from a variety of lightweight materials including several compositions of rigid foams, lightweight cast cement components, lightweight, air entrained and fiber-reinforced materials composed of, for example, recycled materials, etc.

A third manufacturing technique can employ molds to form castings of complete platforms or platform components. These castings can be molded from a variety of lightweight materials including several compositions of rigid foams, lightweight cast cement components, lightweight, air entrained and fiber-reinforced materials composed of, for example, recycled materials, etc.

This written description uses examples to disclose the embodiments, including the best mode, and also to enable those of ordinary skill in the art to make and use the invention. The patentable scope is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities can be performed in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which they are performed.

In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of invention.

It can be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The term “communicate,” as well as derivatives thereof, encompasses both direct and indirect communication. The term “discreet,” as well as derivatives thereof, references to the amount of skin exposed by a user of the garment, rather than the type of style of the garment. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, can mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items can be used, and only one item in the list can be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

The description in the present application should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. § 112(f) with respect to any of the appended claims or claim elements unless the exact words “means for” or “step for” are explicitly used in the particular claim, followed by a participle phrase identifying a function.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, sacrosanct or an essential feature of any or all the claims.

After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.

As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. As used herein, the terms “substantial” and “substantially” means, when comparing various parts to one another, that the parts being compared are equal to or are so close enough in dimension that one skill in the art would consider the same. Substantial and substantially, as used herein, are not limited to a single dimension and specifically include a range of values for those parts being compared. The range of values, both above and below (e.g., “+/−” or greater/lesser or larger/smaller), includes a variance that one skilled in the art would know to be a reasonable tolerance for the parts mentioned.

The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.

Claims

1. A shelter, comprising:

a foundation system configured to be filled in-place at a construction site with concrete; and

a structure mounted to the foundation system, the structure walls and a roof comprising rigid foam insulation plastered with continuous filament winding (CFW), wherein the foundation, walls and roof comprise seamless transitions there between.

2. The shelter of claim 1, wherein the CFW comprises strands or rovings of at least one of glass fiber, carbon fiber, polypropylene or basalt.

3. The shelter of claim 1, wherein the structure does not rotate during manufacturing, and self-tensioning creels of the CFW are applied to the structure on a continuous looped track that encircles the rigid foam insulation as it progresses through a winding station, such that the structure is in compression.

4. The shelter of claim 1, wherein the structure further comprises stand offs located between the rigid foam insulation and the CFW.

5. The shelter of claim 4, wherein the stand offs comprise at least one of basalt rods or fiber reinforced products.

6. A method of fabricating a shelter, comprising:

(a) positioning wall assembly tubes and floor assembly guide rails in a rolling press wall and fixed end wall template for a desired length and width of the shelter;

(b) installing roof panel assembly tubes in the rolling press wall and fixed end wall template for a desired height of the shelter;

(c) positioning a first set of precut foam, tray foundation elements the rolling press wall and fixed end wall template;

(d) installing vertical side wall elements on the tray foundation;

(e) positioning the roof panel assembly flush with and on top of the vertical side wall;

(f) applying adhesive to the tray foundation, vertical side walls and roof panel assembly to form a section of the shelter;

(g) advancing the section of the shelter along the wall assembly tubes and floor assembly guide rails, and repeat steps (a)-(f) for a subsequent section of the shelter; and then

(h) assembling and bonding the sections of the shelter together to form a sub-assembly.

7. The method of claim 6, further comprising forming components comprising windows, doors, headers, sill elements from a fiber-reinforced compound.

8. The method of claim 7, installing the components, plumbing vents, conduit penetrations, plugs, switches and lighting boxes on the sub-assembly.

9. The method of claim 6, further comprising installing CFW on the sub-assembly.

10. The method of claim 9, further comprising installing stand offs on the sub-assembly before installation of the CFW.

11. The method of claim 9, fiber-reinforced plastering the CFW to the sub-assembly.

12. A foundation for a shelter, comprising:

a portable tray configured to support the shelter, the portable tray comprising an interior configured to be filled or injected with a mass, and anchor elements configured to be anchored to an underlying formation.

13. The foundation of claim 12, wherein the portable tray is configured to be installed on piers or rails in a permanent application.

14. The foundation of claim 12, wherein the portable tray comprises sleeves for manufacturing, assembly or transport.

15. The foundation of claim 12, wherein the portable tray comprises pre-cut foam.

16. The foundation of claim 12, wherein the portable tray comprises compartments for at water storage, solar equipment, battery-powered electricity and HVAC.

17. The foundation of claim 12, wherein the portable tray comprises connections for external power, AV, fiber, water and sewer services through internal raceways and channels.

18. The foundation of claim 12, wherein the mass comprises at least one of concrete, sand, stone, precast weights or water to ballast and provide structural stability for the portable tray.

19. The foundation of claim 12, wherein the portable tray comprises a modular tiling system comprising movable functional components comprising a toilet, sink, speaker, lights, furniture, electronic equipment, cooking surface, lock box, trash bin and HVAC.

20. The foundation of claim 12, wherein the portable tray comprises sensors to detect tank levels and signal refill times.