Poured-in-place concrete construction components and method of construction

Abstract

A lightweight poured-in-place concrete builiding component and method of construction in which a plurality of spaced apart structural members with outer regions and a retaining layer system create a segmented form into which a lightweight concrete slurry is poured. The retaining layer system includes a lath which extends across the structural members on at least one outer region of the structual members. The lath is configured to simultaneously support a significant amount of the lightweight concrete slurry within a segmented form and allow a small amount to exude through the lath, thereby reinforcing a concrete component once cured. Alternative embodiments include the introduction of a barrier between a significant portion of a lath and concrete slurry to, at least reduce the amount on concrete which exudes-through the lath. Other altnerative embodiments include the introduction of insulative materials to the concrete slurry to enhance the insulative qualitites of a concrete component.

Description

TECHNICAL FIELD [0001] This invention relates generally to lightweight concrete used in the construction of buildings and other structures. More particularly, it relates to poured-in-place lightweight concrete walls and horizontal components for use as a floor, ceiling or roof of a building or other structure. Lightweight concrete walls, floors, ceilings or roofs formed in such a manner are easy to construct, build out and finish and when cured, are resistant to impact loads. BACKGROUND ART [0002] In general, concrete has been used to construct walls and horizontal components such as floors, ceilings and flat roofs. However the construction of each type of slab presents a number of challenges. With respect to wall and floor slabs, the adjacent earth must be stabilized and prepared to receive and hold the concrete slurry to be poured. Without proper stabilization of the adjacent earth, a cured wall or floor slab may shift or crack. Preparation may include trenching and leveling the a...

AI Technical Summary

Benefits of technology

[0008] In another embodiment, a layer of insulative material is fixed within said lightweight concrete slurry. While described here as a retaining layer system between a pair of structural members, the metal lath and / or the barrier may extend over both sides of a plurality of structural members so as to form an extended retaining layer system support. When the lightweight concrete cures, the exposed face of the retaining layer system or metal lath may be finished with a veneer such as stucco to give the surface an attractive finish. Any forms are removed, and the surface may be finished with a covering.

Problems solved by technology

However the construction of each type of slab presents a number of challenges.

Without proper stabilization of the adjacent earth, a cured wall or floor slab may shift or crack.

Typical prefabricated modular slabs are heavy and pose unique challenges in lifting to the final position at the construction site.

As can be appreciated, additions after-the-fact require cutting the concrete or making workarounds, both of which are very expensive.

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