Method and apparatus for making foam blocks and for building structures therewith

Abstract

Foam blocks may be manufactured using a two part urethane foaming agent or the like at the construction site using a mold that may be disassembled into a plurality of component pieces for ease of transportation and to facilitate removal of a block. Preferably, the blocks are formed in the mold in which a facing is placed such that the facing is bonded to the foam of the block. A wall constructed from successive courses of blocks will have intersecting horizontal and vertical channels which may be filled with concrete and reinforcing rod to produce a wall with high horizontal and vertical load capacity as well as superior insulating properties.

Description

TECHNICAL FIELD [0001] The present invention relates to methods and apparatus for making foam blocks and for using such foam blocks for constructing building structures, particularly wall structures, therewith. BACKGROUND OF THE INVENTION [0002] In many less developed countries, and in underdeveloped areas in many countries there is a need for building low cost housing units and other structures in an expeditious, cost-effective manner using local labor resources that may not be highly skilled and trained in modern construction methods. However, many of the present alternative construction methods in such areas, such as wood frame construction and concrete construction, require skilled labor and the hauling of substantial equipment and materials to the construction site. [0003] Construction methods are known which use various types of foam forms and foam blocks. These forms and blocks contain voids that are filled with concrete and reinforcing rod (“rebar”) and the forms or blocks a...

AI Technical Summary

Benefits of technology

[0007] The molds for making the blocks can be advantageously fabricated from a plurality of steel plates with appropriate fittings mounted thereon. When so constructed, the molds may be broken down for easy handling and transportation to the construction site. When the mold is reassembled, a facing may be positioned therein, together with mold spacers for creating voids in the blocks, and the components for making the foam may be added to the mold. The mixed components expand rapidly within the mold and bind to the facing.

Problems solved by technology

However, many of the present alternative construction methods in such areas, such as wood frame construction and concrete construction, require skilled labor and the hauling of substantial equipment and materials to the construction site.

However, they all require that the bulky foam blocks or forms and other materials be transported to the construction site.

This is inconvenient for construction undertaken in underdeveloped or remote locations.

Furthermore, the storage of the blocks at the source and at the construction site is inconvenient.

In addition to the foregoing, the prior construction systems do not provide an exterior finish on the blocks or forms.

Thus, conventional exterior finishing methods, which may involve the use of bulky and expensive materials, may have to be used thereon.

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